Graco 309790P - 8900 Proportioner Instructions

Instructions - Parts

8900 Proportioner

309790P

Configured product offering for dispensing fixed or variable ratio of two fluids.

2000 psi (13.8 MPa, 138 bar) Maximum Working Pressure

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

See page 8 for pump model numbers, ratios and

working pressures.

Fixed-ratio proportioner shown

TI2761A

2

Contents

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . 3

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . 5

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Major Components . . . . . . . . . . . . . . . . . . . . . . . 5

Ratio Proportioning . . . . . . . . . . . . . . . . . . . . . . . 5

System Components and Operation Overview . . 5

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 10

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Set the Ratio (variable ratio models only) . . . . . 14

Output Charts/Ratio Settings . . . . . . . . . . . . . . 15

Before You Load Material . . . . . . . . . . . . . . . . . 18

Load Component A . . . . . . . . . . . . . . . . . . . . . . 19

Prime Pump A . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Load Component B . . . . . . . . . . . . . . . . . . . . . . 21

Prime with Component B . . . . . . . . . . . . . . . . . 24

Fill the 8900 Proportioner with Material . . . . . . 24

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Pressure Relief Procedure . . . . . . . . . . . . . . . . 27

Dispense Mixed Material . . . . . . . . . . . . . . . . . . 28

Changing Component A Drum . . . . . . . . . . . . . 30

Changing Component B Pail . . . . . . . . . . . . . . . 31

Filling Component B Pressure Tank . . . . . . . . . 32

Daily Procedures . . . . . . . . . . . . . . . . . . . . . . . . 34

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8900 Proportioner Operating Pressures . . . . . . 36

Air Supply Troubleshooting Chart . . . . . . . . . . . 37

Pump Troubleshooting Overview . . . . . . . . . . . 38

Troubleshooting Guide: Feed pumps . . . . . . . . 39

Troubleshooting Guide: 8900 Proportioner . . . . 40

Troubleshooting Guide: Manifold/Mixer . . . . . . . 41

Preventive Maintenance . . . . . . . . . . . . . . . . . . 42

Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . 43

Repair the Cylinder (Fixed Ratio) . . . . . . . . . . . 43

Replace Air Valve . . . . . . . . . . . . . . . . . . . . . . . 45

Disassemble Fluid Valve . . . . . . . . . . . . . . . . . . . . 46

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

8900 Proportioner, Fixed Ratio . . . . . . . . . . . . . 48

8900 Proportioner, Variable Ratio . . . . . . . . . . . 50

Cylinder Assemblies . . . . . . . . . . . . . . . . . . . . . 52

Limit Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Pump Feed Module Selection for Component A or

Component B . . . . . . . . . . . . . . . . . . . . . . . 56

20:1 President on 5 Gallon Ram . . . . . . . . . . . . 56

34:1 Senator on 5 Gallon Ram . . . . . . . . . . . . . 58

23:1 Monark on 5 Gallon Ram . . . . . . . . . . . . . 60

20:1 President on 55 Gallon Ram . . . . . . . . . . . 62

34:1 Senator on 55 Gallon Ram . . . . . . . . . . . . 64

31:1 Bulldog on 55 Gallon Ram . . . . . . . . . . . . . 65

20:1 Senator on 55 Gallon Drum . . . . . . . . . . . . 66

9:1 DynaMite on 1 Gallon Can Ram . . . . . . . . . 67

10 Gallon Press Tank with 15:1 Booster . . . . . . 68

10:1 President 5 Gallon Pail Cover . . . . . . . . . . 69

Mix Kit Selection . . . . . . . . . . . . . . . . . . . . . . . . 70

Cartridge Fill Medium Viscosity Wide Ratio . . . 70

Cartridge Fill High Viscosity Wide Ratio . . . . . . 72

Brush Grade High Viscosity Wide Ratio . . . . . . 74

2K UltraLite 20 ft Automatic . . . . . . . . . . . . . . . . 76

2K UltraLite 20 ft Hand Gun . . . . . . . . . . . . . . . 77

2K UltraLite 15 ft Hand Gun Wide Ratio Moisture

Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

High Volume Static Mix Manifold . . . . . . . . . . . . 79

High Volume Static Mix Kit with Pump Pilots . . . 80

Stanchion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 82

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 86

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 86

309790P

309790P 3

Manual Conventions

Warning

WARNING

A warning alerts you to the possibility of serious injury or death if you do not follow the instructions.

Symbols, such as fire and explosion (shown), alert you to a specific hazard and direct you to read the indi-

cated hazard warnings (pages 4-5) for detailed infor-

mation.

Caution

CAUTION

A caution alerts you to the possibility of damage to or destruction of equipment if you do not follow instructions.

Note

A note indicates additional helpful information.

4

Warning

Skin Injection Hazard

Spray from the gun, hose leaks, or ruptured components can inject fluid through skin and cause extremely serious injury, including need for amputation. Fluid splashed in the eyes or on skin can cause serious injury.

• Fluid injected into skin might look like just a cut, but it is a serious injury. Get immediate surgical treatment.

• Do not point the gun at anyone or any part of the body.

• Do not put hand or fingers over the spray tip/nozzle.

• Do not stop or deflect leaks with hand, body, glove or rag.

• Do not “blow back” fluid; this is not an air spray system.

• Always have tip guard and trigger guard on the gun when spraying.

• Check gun diffuser weekly. Refer to gun manual.

• Check trigger safety operation before spraying. Lock trigger safety when you stop spraying.

•

Follow the Pressure Relief Procedure, page 27, if the spray tip/nozzle clogs and before cleaning,

checking or servicing the equipment.

• Tighten fluid connections before operating equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not repair high pressure couplings; replace the entire hose.

• Fluid hoses must have spring guards on both ends to help protect them from rupture caused by kinks or bends near the couplings.

Toxic Fluid Hazard

Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on skin, swallowed, or inhaled.

• Know specific hazards of the fluid. Read fluid manufacturer’s warnings.

• Wear appropriate protective clothing, gloves, eyewear, and respirator.

309790P

309790P

Warning

Equipment Misuse Hazard

Equipment misuse can cause equipment to rupture, malfunction, or start unexpectedly and cause serious injury.

• This equipment is for professional use only.

• Read manuals, tags, and labels before operating equipment.

• Use equipment only for its intended purpose. If you are uncertain, call your Graco distributor.

• Do not alter or modify equipment. Use only genuine Graco parts and accessories.

• Check equipment daily. Repair or replace worn or damaged parts immediately.

• Do not exceed maximum working pressure of lowest rated system component.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data section of all equipment manuals. Read fluid and solvent manufacturer’s warnings.

• 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 kink or overbend hoses or use hoses to pull equipment.

• Comply with all applicable local, state, and national fire, electrical, and other safety regulations.

• Do not use excessive drum separation air pressure as the drum could rupture. Make sure the drum is not damaged and the ram plate is free to exit the drum before applying air pressure.

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 object being sprayed. See Grounding, page 12.

• If you experience static sparking or electric shock, stop operation immediately. Identify and correct the problem.

• Provide fresh air ventilation to avoid building up flammable fumes.

• Keep the spray area free of debris, including solvent, rags, and gasoline.

• Extinguish all sources of flames in the spray area, including pilot lights and cigarettes.

• Do not turn on or off any light switch or plug or unplug electrical equipment in the spray area while operating or if fumes are present.

• Do not operate a gasoline engine in the spray area.

• Keep a fire extinguisher in the work area.

Moving Parts Hazard

Moving parts, such as priming piston and wiper plate, can pinch or amputate fingers. Keep clear of moving parts when starting or operating equipment and when equipment is pressurized.

• Keep hands and fingers away from the priming piston.

• Keep hands away from the ram wiper plate and pail lip.

•

Before servicing, follow the Pressure Relief Procedure, page 27, to avoid equipment startup.

5

6

Theory of Operation

Theory of Operation

Use

The 8900 Proportioner is used with two component materials where one or both components is high viscosity. This is typically found in the sealant and adhesive industry, where special requirements for loading and pumping necessitate the use of the 8900 proportioning system.

Major Components

The major components of the 8900 Proportioner system include the:

• Component A or major volume metering cylinder

• Component B or minor volume metering cylinder

• Component A or major volume feed supply

• Component B or minor volume feed supply

Ratio Proportioning

The A and B cylinders are positive displacement metering cylinders. Positive displacement cylinders displace a defined volume of fluid for a given stroke length.

On fixed ratio units, the volumetric ratio is the ratio of the area of the component A displacement cylinder to the area of the component B displacement cylinder. At a 1:1 ratio, the displacement cylinders are the same size. On higher ratio units the component A cylinder is usually the larger of the two. The ratio of the components is the difference in effective area between the cylinders.

On variable ratio units, the component B cylinder has an adjustable stroke length. The component A cylinder has a fixed stroke length. By setting the stroke adjustment to different points on the connecting linkage, you can change the stroke length of the B cylinder, which changes the mix ratio. You can calculate the material mix ratio from the ratio of the cylinder displacement volume.

Note that the mix ratio of the 8900 Proportioner is achieved by volumetric ratio of component A to component B and not by weight. These two ratios are often different depending on material properties.

System Components and

Operation Overview

Feed Systems - Feed Pumps

Load the Feed Pumps and Proportioner

The A and B feed pumps/cylinders must completely fill

(prime) on both strokes to ensure accurate material displacement.

With high viscosity materials, it is difficult for material to flow into the pump. Individual feed pumps are used to supply these materials under pressure to the 8900 Proportioner. When air is trapped in the feed system due to improper loading, a condition called cavitation occurs.

If cavitation occurs, part of the downstroke will be used to fill the vacuum before any material is actually displaced. Since the total stroke length is used to calculate mix ratio, this may result in an off-ratio condition.

To prevent cavitation with higher viscosity materials, both cylinders are pressure fed. The A pump is pressurized by a pneumatic ram supply unit applying a downward force on a 55-gallon plate fitted into the drum. A shovel action pump fluid inlet further aids in pump priming. Component B is delivered to the B pump by pressure fed 5- or 55-gallon supply modules, depending on the volumetric ratio of the material.

Pneumatic ram assisted feed pumps may not be required for lower viscosity materials.

Feed Systems - Alternative Feed Supplies

Header or other feed systems may be used to supply A and B materials to the 8900 Proportioner. Generally these feed systems are provided by others and are not addressed in this manual. This manual applies only to the Graco Configured 8900 Proportioner system.

309790P

Theory of Operation

Pump Fluids to the Mixer

Fluid is pumped through the proportioner to a mix chamber or to a 2-component dispense gun, where component A and component B are first introduced before being mixed with a static mixer.

A fluid injector nozzle/check valve injects component B into component A at the mix chamber. When enough pressure builds up, the check valve opens and component B flows into the mix chamber. This means that during flow conditions with two positive displacement cylinders linked together, the pressures at the mix point are equal.

Any pressure differences noted on the gauges while running, reflect differences in the pressure lost by each fluid getting from the gauge to the mix point. These pressure drops are caused by hoses and fittings in conjunction with material viscosity.

Mix the Fluids

Both components leave the mix chamber and enter a static mixer where they are mixed to a homogeneous blend. The mixer consists of a series of left and right-hand spiral elements. This is true for both mix chamber and 2-component mix gun.

When the components are pumped through the mixer, they are progressively divided and recombined. Static mixers used on the 8900 Proportioner system include the tri-core mixer, flexible hose mixer, or disposable mixer.

Ratio Checks

On the variable ratio model, a ratio check station option verifies the volumetric mix ratio of the two components.

It is located at the outlet blocks. With all outbound fluid valves closed, each component flows through individual ball valves opened by a common handle into containers.

Volumetric mix ratio can be calculated from the weight of each component or by direct measurement. Ratio checks are performed with the back pressures set to actual operating pressures to simulate the normal back pressures created by the mix chamber and gun.

Dispense Valve

An extrusion flow gun is commonly used as the application device. It has a final or clean up mixer installed in the handle. Various extrusion nozzles are available for caulking or sealing applications.

Some 8900 Proportioners use a 2K disposable mixer

element dispense valve instead of the flow gun.

The 8900 Proportioner can be used in automatic assembly lines with the addition of a logic interface.

309790P 7

8

Models

Models

Refer to form 684041 for selection information.

E

F

G

H

A

B

C

D

J

K

N

Code C

E

F

G

H

A

B

C

D

J

K

N

Model

890-D

Code A

7

A

5

6

B

D

3

4

1

2

Code B

Description

Power Valved Passive Proportioner

Proportioner Selection (“A” Cyl. / “B” Cyl.)

1:1 Fixed (1000/1000)

2:1 Fixed (1000/500)

2.5:1 Fixed (250/100)

4:1 Fixed (1000/250)

5:1 Fixed (500/100)

10:1 Fixed (1000/100)

9:1 Fixed (1000/111)

1:1 to 4:1 Variable (500/500)

2:1 to 8:1 Variable (500/250)

5:1 to 20:1 Variable (500/100)

Pump Feed Module Selection for Component A

20:1 President on 5 Gallon Ram

34:1 Senator on 5 Gallon Ram

23:1 Monark on 5 Gallon Ram



31:1 Bulldog on 55 Gallon Ram

20:1 Senator on 55 Gallon Drum

9:1 DynaMite 1 Gallon Can Ram

10 Gallon Press Tank with 15:1 Booster

10:1 President 5 Gallon Pail Cover

None

Pump Feed Module Selection for Component B



23:1 Monark on 5 Gallon Ram



31:1 Bulldog on 55 Gallon Ram

20:1 Senator on 55 Gallon Drum

9:1 DynaMite 1 Gallon Can Ram

10 Gallon Press Tank with 15:1 Booster

10:1 President 5 Gallon Pail Cover

None

Module Number

570371

570372

570373

570374

570375

570376

246557

570377

570378

570380

Module Number

965571

965597

570142

570114

965572

570141

570309

570249

570037

570264

Module Number

965571

965597

570142

570114

965572

570141

570309

570249

570037

570264

309790P

Code D

7

8

5

6

3

4

1

2

9

10

N

Code E

1

2

N

Mix Kit Selection

Cart Fill Medium Viscosity Wide Ratio

Cart Fill High Viscosity Wide Ratio

Brush Grade High Viscosity Wide Ratio

2K UltraLite 20 ft Automatic Wide Ratio

2K UltraLite 20 ft Automatic Close Ratio

2K UltraLite 20 ft Hand Gun Wide Ratio

2K UltraLite 20 ft Hand Gun Close Ratio

High Volume Static Mix Manifold

High Volume Static Mix Kit with Pump Pilots

2K UltraLite 15 ft Hand Gun Wide Ratio Moisture Lock

None

Mounting Type Selection

Stanchion

Boom Assembly

None (mount on 3 in. 55 gallon ram)

Models

Module Number

570248

570318

570358

570144

570362

570363

570091

570391

570263

246588

Module Number

570071

246589

309790P 9

Installation

Installation

Typical Installation

Figures 1-3 are only guides for selecting and installing system components and accessories. Contact your

Graco distributor for assistance in designing a system to suit your needs.

Location

Position the feed modules so the pump and ram are easily accessible. Ensure that there is sufficient overhead clearance when the ram is fully raised. Refer to the ram manual for clearance dimensions.

Using the holes in the ram base as a guide, drill four holes for 1/2 in. (13 mm) anchors.

Key:Figs. 1 and 2

A System Air Shutoff Valve (bleed-type)

B Main Air Filter

C Component B Ram Directional Valve

D Component B Ram Air Pressure Regulator

E Component B Air Supply Valve (bleed-type)

F Component B Air Supply Regulator

G Component A Air Supply Valve

H Component B Outlet Pressure Gauge

J Component B Feed Pressure Gauge

K Component A Feed Pressure Gauge

Check that the ram base is level in all directions. If necessary, level the base using metal shims. Secure the base to the floor using 1/2 in. (13 mm) anchors that are long enough to prevent the ram from tipping.

L Component A and Component B Feed Pump Air

Motor Lubricator

M Component B Ram Plate with Vent Stick or Valve

N Component A Ram Plate with Drum Vent Valve

O Component A Pump Air Regulator

P Component A Ram Directional Valve

Q 2K Ultra Lite Gun with Disposable Mixers

R Component A Ram Air Pressure Regulator

S Accessory/Gun Air Supply Valve

Q

G

H

J

(behind)

K

(behind)

E

R

P

D

C

F IG . 1:

M F

O

S

IIN ST U CC T O N

RE EA AD M A N U U A BE EFFO RE PE ER AT N G G

D IIS SP EN SE XE D M M A ER A LL A S E P RG G E N D SH T--D D O W N

D JJU U S RA A T

RU M O R P PA H A G E

RE EFFIILLLLIIN G P

((IIFF E

ES

EQ

SS

ED

RE

D ))

""BB"" PPUU M

P RE

A D

ES

U S

SS

ST

U R

TM

RE

M E

E

N T T

""AA"" PPUU M

P ES SU U R E

AD D JJU ST M E T

PU M P S

8 90 0

PPRROOPPOORRTTIIOONNEERR

A R N IIN u rre su es ss h p p rre H iig g h d e e d v iic ev e ffo c e p rro orr p siio ss offe es all u u s n a on on n lly se e o y..

sttrru n s c ttiio u c ea Re d iin ad g s n iin n g w a arrn u a n u b e all b n m on m a an orre effo op e o erra p e n g attiin se b s g .. O O b v e errv allll e a

M A IIN R

O N N

M N A

T

R

A

L

B

N

TI3258Ax

10 309790P

Installation

Component B

Supply Header

Component B

Fluid Regulator

H

J

(behind)

K

(behind)

S

""BB"" PPUU M

P RE SS SU RE E

A D D JJU ST M E T

IIN ST RU TIIO N S

RE AD D M AN U A ALL B

SP PE SE M IIX ED M A TE RIIA

RE E O ER RA G

A S SE U R RG AN D S H U D O O W

A D D JJU ST O W W R A T TE

RU U M R P PA A N N G

EFFIILLLLIIN N G

((IIFF E

PR

EQ

ES

U IIP

U R

ED

PO O T

""AA"" PPUU M

P RE SS U R

AD D JJU ST N T T

O

P

O FFFF

U M

O N N

8 90 0

PPRROOPPOORRTTIIOONNEERR

W A R N IIN G siio ss offe es n a on u s all u on n lly e o se y..

v iic ev e d d e e ffo c e orr p p rro h p p rre H iig g h su u rre ss es allll e a errv v e b s se g .. O O b attiin n g p e erra e o op effo orre all b b e n u u a m a an on n m u c c ttiio n s sttrru ad d iin Re ea w a arrn g s n g n iin

M A IIN R

O N N

M A IIN R

N LLE T

L

B

A

F IG . 2:

Key:F IG . 3

Q 2K Gun

V Disposable Mixer Element

W Component B Injector Valve

Supply header system supplied by others

(not covered in this manual).

Component A

Supply Header

Component A

Fluid Regulator

X Air Trigger Pilot

Y Component B Supply

Z Component A Supply

W

Y

F IG . 3

309790P

X

Z

Q

V

TI3262A

H C

11

Installation

Ground

WARNING

The system must be properly grounded. Read warnings, page 5. Follow the instructions below.

Pump: use the ground wire and clamp (supplied). There are two styles of ground connections on pump air motors.

If you have the ground screw (a) shown in F IG . 4

(King air motor only), order part no. 222011 ground wire, ring terminal, and clamp assembly (b). To install

222011, remove the ground screw (a) and insert it through the eye of ring terminal (c), then tighten ground

screw back into air motor as shown in F IG . 4. Connect

the other end of the wire to a true earth ground.

c a b

Air and fluid hoses: use only electrically conductive hoses with a maximum of 500 ft (150 m) combined hose length to ensure grounding continuity. Check the electrical resistance of your air and fluid hoses. If the total resistance to ground exceeds 29 megohms, replace the hose immediately.

Air compressor: follow manufacturer’s recommendations.

Spray gun/dispense valve: ground through connection to a properly grounded fluid hose and pump.

Fluid supply container: follow your local code.

Substrate: follow your local code.

Solvent pails used when flushing: follow your local code. Use only conductive, metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

To maintain grounding continuity when flushing or

relieving pressure: hold a metal part of the gun/dispense valve firmly to the side of a grounded metal pail, then trigger the gun/valve.

F IG . 4: Ground Screw (King air motors only)

If you have the ground screw (d) shown in F IG . 5,

loosen the grounding lug locknut (g) and washer (f).

Insert one end of the ground wire (e) into the slot in lug

(d) and tighten the locknut securely. Connect the other end of the wire to a true earth ground. Order 237569 ground wire and clamp assembly.

e g f d

F IG . 5 Ground Screw

12 309790P

Installation

Flush

WARNING

Read warnings, pages 4-5. Follow Ground instructions, page 12.

• The equipment was tested with light, soluble oil.

Flush the system before loading material to avoid contamination.

• Flush at the lowest pressure possible and check connectors for leaks.

To flush the system:

1.

On the ram-mounted component A supply units, you must remove the drum ram plate to immerse the A pump in a solvent pail. To remove the plate: a.

Disconnect the blow-off air line from the ram plate.

b.

Disconnect the tie rod nuts from the ram cross beam.

c.

Remove seal plates between the pump and ram.

d.

Loosen ram tie rods from plate and remove plate.

e.

If a pail ram is used with the component B supply, remove the pail plate by loosening the 2 set screws.

f.

Position the solvent pail so the pump inlet is in the solvent.

2.

Flush the system and all hoses by very slowly opening the motor control valves until 30 psi (207 kPa,

2.1 bar) is shown on the component A outlet pressure gauge.

Flush for 1-2 minutes, then close the motor control valves.

CAUTION

To avoid damaging the pump, open the motor control valves very slowly to prevent a pump runaway condition.

It is normal for the air valve to exhaust air when it is partially open.

3.

Check connectors for leaks and tighten them if necessary.

4.

Remove the solvent pail(s) from the pump inlets.

5.

Operate the pump(s) at low pressure to remove excess solvent.

6.

Reinstall the drum or pail ram plates.

Use solvent that is compatible with the equipment wetted parts and the material you will dispense.

g.

Support the ram(s) so that the pump inlet and piston will not hit the base plate or pail bottom.

h.

Make sure both component A and component B outlet hoses are open.

309790P 13

Setup

Setup

WARNING

Read warnings, pages 4-5, before operating equipment.

Set the Ratio (variable ratio models only)

Adjust ratio

The ratio of this unit is produced partially by the difference in the area of the metering cylinders and partially by the position of the adjustable fulcrum point in the Unibar linkage assembly. With the fulcrum point in the center, each meter cylinder strokes 3 in. (10.16 cm). In the center position, the dispense ratio is the same as the meter cylinder ratio.

The linkage is adjustable depending on the location of the fulcrum point. The linkage must be adjusted for each material application so the combined linkage and meter cylinder ratio equals the desired material mix ratio by volume. The ratio may be checked by weight, but the machine meters by volume and that ratio must be known before proceeding.

The initial linkage adjustment point can be calculated by

inserting known values into the formula on page 35. The

result is the distance in inches from the center of the fulcrum point to the center of the component B meter cylinder. For convenience, measure the distance between the grease fitting on the top of the fulcrum and the center of the component B cylinder meter rod.

F IG . 6

D ec re as e

B

V o lu m e

I n cr ea se

Set Scale

Refer to the 8900 Proportioner Output Charts on the following pages to set the scale. Make final adjustments

after the material is loaded. See instructions on page 33

for detailed ratio check instructions.

14 309790P

Output Charts/Ratio Settings

8900 Proportioner, 1:1 - 4:1 Variable Ratio

Mix Ratio by Volume

1

1.5

2

2.5

3

3.5

4

12

Scale Setting

5.63

7.13

8.13

8.85

9.38

9.80

10.13

Minor Stroke

3.00

2.00

1.50

1.20

1.00

0.86

0.75

10

8

6

4

2


0

Scale Setting

Minor Stroke

1

5.63

3.00

1.5

7.13

2.00

2 2.5

8.13

1.50

8.85

1.20

3

9.38

1.00

3.5

9.80

0.86

4

10.13

0.75

Setup

309790P 15

Setup



6

7

8

4

5

2

3

12

Scale Setting

5.63

7.13

8.13

8.85

9.38

9.80

10.13

Minor Stroke

3.00

2.00

1.50

1.20

1.00

0.86

0.75

10

8

6

4

2


0

Scale Setting

Minor Stroke

2

5.63

3.00

3

7.13

2.00

4

8.13

1.50

5

8.85

1.20

6

9.38

1.00

7

9.80

0.86

8

10.13

0.75

16 309790P



15

17

20

5

7

10

12

12

Scale Setting

5.63

7.13

8.13

8.85

9.38

9.80

10.13

Minor Stroke

3.00

2.00

1.50

1.20

1.00

0.86

0.75

10

8

6

4

2

0


Scale Setting

Minor Stroke

5

5.63

3.00

7

7.13

2.00

10

8.13

1.50

12

8.85

1.20

15

9.38

1.00

17

9.80

0.86

20

10.13

0.75

Setup

309790P 17

Setup

Before You Load Material

1.

Check fluid and air lines and tighten if necessary.

2.

Make sure there is a minimum overhead clearance of 110 in. (279 cm) for 55 gallon supply.

3.

Fill air line lubricator for the 8900 Proportioner module with SAE 10 W non-detergent oil (not included).

4.

Fill the pump A and B wet cups 2/3 full with Graco

T.S.L. fluid (throat seal lubricant) or lubricant compatible with material being pumped.

ISO pump oil is used with moisture sensitive component B.

5.

Close (turn fully counterclockwise) all air regulators.

6.

Connect the 3/4 in. (19 mm) ID x 10 ft (3.05 m) air hose (provided) to your air supply.

Do not use a restrictive quick-disconnect. The air supply pressure must be consistently above the pressure you set on the main air motor regulator.

G

Wet Cup

N

TI3263Ax

F

IG

. 7

18 309790P

Setup

Load Component A

1.

Make sure all air regulators on proportioner module are fully closed.

2.

Open the main air supply shutoff valve (A), F IG . 8.

3.

Place the ram lever (P-F IG . 10) in the UP position.

N

W

CAUTION

As the ram rises, make sure hoses do not catch on any components. If a hose catches, immediately stop the ram (move lever to NEUTRAL position) and correct the problem. Lower the ram if necessary to redirect hoses.

4.

Slowly turn the ram air regulator (R) clockwise until the ram begins rising.

F IG . 9

WARNING

When lowering the ram, keep hands and body away from the ram plate and material drum. Read warnings,

page 5.

9.

With hands away from the pail and wiper plate (N), set the ram lever (P-F IG . 10) to NEUTRAL (horizontal position). Let the ram lower until the wiper plate rests on the pail lip.

10. Lower the ram plate into the drum (move ram lever to DOWN position).

CAUTION

Do not lower ram if a drum is not in place. Doing so can damage drum centering guides.

O

A

F IG . 8

5.

When ram is fully raised, apply a thin coating of lubricant to the ram plate drum seals.

6.

Open the material container. Remove any packing materials, and inspect for material contamination. If the container has a plastic liner, pull it tightly over the sides of the container, and secure the liner in place with tape wrapped below the top drum rim.

7.

Position the drum so it rests evenly between the centering guides and is fully backed into the stops located near the back of the ram base plate.

8.

Open the drum vent valve (W), F IG . 9.

R

Ram Separation

Air Button

P

F IG . 10

11. After the ram plate seals contact the drum, adjust the ram air regulator (R) to about 30-50 psi

(207-345 kPa, 2.1-3.4 bar).

12. When the ram stops and material fills the bleed port

(or air stops bleeding out), close the drum vent valve

(W), F IG . 9.

13. Supply unit is now ready to fill lines to proportioner.

309790P 19

Setup

Prime Pump A

1.

Place a waste container under the pump bleed valve located behind the displacement pump outlet, F IG .

11. Using an adjustable wrench, open the bleed valve counterclockwise 1/3-1/2 turn.

2.

Slowly open the component A air motor shutoff

valve (G), F IG . 7. Make sure the pump begins to

cycle and material flows from the bleed valve after several cycles of the pump, F IG . 11.

If the pump does not cycle, close the air shutoff valve (G), adjust the air motor regulator (O-F IG . 8) up 5 psi (34 kPa, 0.3 bar) and repeat step 2.

Never adjust the regulator by more than 5 psi (34 kPa, 0.3 bar) increments.

3.

Operate the pump until it moves smoothly in both directions with no air popping or erratic movement, then close the air motor shutoff valve (G).

4.

Close the bleed valve, F IG . 11.

Bleed Valve

F IG . 11

20 309790P

Setup

Load Component B

Follow the procedure for the type of supply equipment being used.

Pneumatic Pail Ram and Piston Pump

1.

Close all air regulators and air valves.

2.

Set the pail ram air regulator (D) to 40 psi (0.28

MPa, 2.8 bar), F IG . 12.

3.

Push the ram directional lever (C) to the UP position and let the ram rise to its full height.

4.

When ram is fully raised, apply a thin coating of lubricant to the ram plate drum seals.

5.

Remove the component B pail cover. If the material has separated, carefully stir it with a metal or plastic rod until it is mixed. Do not use wood to stir as it can splinter and contaminate the material. Do not mix air into the material.

6.

Set the pail on the ram base. Slide it back toward the ram tube and supports and center it under the wiper plate. To prevent air from being trapped under the wiper plate, scoop fluid from the center of the pail to the sides to make the surface concave.

WARNING

When operating the pump or raising or lowering the ram, keep hands away from the wiper plate, fluid con-

tainer lip, and pump intake. Read warnings, page 5.

7.

With hands away from the pail and wiper plate, set the ram lever (C) to NEUTRAL (horizontal position).

Let the ram lower until the wiper plate rests on the pail lip.

8.

Ensure the pail is aligned with the wiper plate.

9.

Push the ram directional lever (C) DOWN and increase ram air pressure until plate completely engages into the pail.

10. Slowly unscrew the vent stick until you hear air escaping. When air is evacuated, set the ram lever

(C) to NEUTRAL and lower ram pressure to 20-30 psi (138-207 kPa, 1.4-2.1 bar).

11. Unscrew the vent stick and put the ram lever (M) in the DOWN position, keeping the vent stick over the vent port.

12. Slowly increase down pressure until material seeps from vent port, the quickly refasten vent stick.

309790P 21

Setup

F IG . 12

D

C

M

Wiper Plate

TI3260B

22 309790P

Setup

Pressure Tank with 15:1 Booster

1.

Relieve tank pressure before opening.

2.

Remove the pressure tank lid and any items shipped inside the tank. Make sure the tank is clean, or use the liner supplied.

3.

Be sure the desiccant air dryer is mounted in the component B tank air supply of the proportioner air control module. See F IG . 28, page 32.

4.

Gently roll an unopened pail of component B on the floor for several revolutions to mix it.

5.

Open the pail outlet and carefully pour component B into the tank.

6.

Immediately close the tank by tightening the Thandles (GG) evenly, F IG . 13.

7.

Pressurize the tank with dried air by opening the component B air shutoff valve (S) and the pressure tank air shutoff valve (T), Figures 14 and 15.

F

S

GG

HH

F IG . 14

8.

Set the component B tank air regulator (U) to approximately 40 psi (276 kPa, 2.8 bar).

9.

Check to ensure the air valve (E) to booster pump is turned off and material supply ball valve (KK) is closed.

10. Set feed pump regulator (F) on proportioner assembly to approximately 40 psi (276 kPa, 2.8 bar).

11. The unit is ready to feed material to proportioner.

F IG . 13

From component B pump air regulator on proportioner module.

KK

E

Booster

Pump

U

T

From air manifold on proportioner module.

To component B inlet on proportioner

F IG . 15

309790P

TI3259Ay

23

Setup

Prime with Component B

1.

Place a waste container under the pump bleed valve

located behind the displacement pump outlet, F IG .

16. Using an adjustable wrench, open the bleed

valve counterclockwise 1/3-1/2 turn.

Fill the 8900 Proportioner with

Material

1.

Place a material waste container under dispense

gun (Q) and open gun. F IG . 1, page 10.

2.

Open the main ball valve (A-F IG . 17) on the propor-

tioner assembly. This air valve supplies air to the proportioner control valving and to the feed pump assemblies. All other air shut-off valves on the manifold and feed pump assemblies should be off.

3.

Open the feed pump main air valve (S). This allows the air supply to feed pump assemblies.

4.

Adjust the component B supply pump air regulator

(F) to allow smooth pumping action. Continue until component B flows from the dispense gun into the waste container.

Bleed Valve

F IG . 16

2.

Slowly open the component B air motor shutoff valve (E), F IG . 15. Make sure the pump begins to cycle and material flows from the bleed valve after

several cycles of the pump, F IG . 16.

If the pump does not cycle, close the air shutoff

valve (E), adjust the air motor regulator (F-F IG .

17) up 5 psi (34 kPa, 0.3 bar) and repeat step 2.

Never adjust the regulator by more than 5 psi (34 kPa, 0.3 bar) increments.

3.

Operate the pump until it moves smoothly in both directions with no air popping or erratic movement, then close the air motor shutoff valve (E), F IG . 15.

4.

Close the bleed valve, F IG . 16.

The minor or component B side of material is filled first to minimize waste during initial startup.

5.

Adjust the component A air regulator (O) to allow smooth pumping action.

6.

Pump until component A and component B flow from the gun into the waste container. When the material is bubble-free, all air has been purged from the system.

7.

Turn off air supply valve (S).

8.

Close dispense gun.

9.

The 8900 Proportioner is now filled with components A and B and ready for operation.

24

F IG . 17

F O S A

309790P

2K UltraLite Disposable Mixer Gun Models

Follow steps 10-12.

10. Fit the hose to the gun. Trigger the gun into a waste container.

11. Open the component B feed air shutoff valve (E-F IG .

15). Component B will feed through the metering cylinder to the mix gun.

12. When bubble free material is dispensed, stop triggering the gun.

All Models

The system is now ready to dispense mixed material.

CAUTION

The materials will cure after mixing. Purge the mixer, hose, and gun with clean material before the material begins to cure.

Setup

309790P 25

Setup

26 309790P

Operation

Operation

Pressure Relief Procedure

WARNING

Read warnings, page 4, and follow the Pressure

Relief Procedure whenever you:

• are instructed to relieve pressure

• stop dispensing

• check or service any of the equipment

• install or clean the nozzle.

1.

Purge mixed material if necessary. See page 29.

2.

Close the main air shutoff valve (A), F IG . 18.

3.

If a component B pressure tank is used, open its

vent (refer to page 23).

4.

Hold a metal part of the gun firmly to the side of a grounded metal pail, and trigger the gun to relieve pressure.

5.

For both component A and component B, open the respective pump bleed valves, having a waste container ready to catch the drainage, F IG . 19.

Bleed Valve

F IG . 18

A

F IG . 19

6.

Manually activate the limit valve (item 26 on page

48), to cause the 4-way valve to shift, fully relieving

pressure within the proportioner.

7.

If you suspect that the nozzle or hose is completely clogged, or that pressure has not been fully relieved

after following the steps above, very slowly loosen the tip retaining nut or hose end coupling and relieve pressure gradually, then loosen it completely, and clear the nozzle or hose.

309790P 27

Operation

Dispense Mixed Material

CAUTION

Make sure the component B relief valve is operational and free from blockage at all times. See manual

308547. If the relief valve fails, the overpressure rupture disc opens and component B is diverted to a waste container mounted on the ram base plate.

8900 Proportioner with Static Mix Chamber

Kits

1.

Load the material. See page 19.

2.

On the variable ratio machine, set ratio (see page

14). On the fixed ratio machine, proceed to step 3.

3.

Open the pump A and pump B air shutoff valve (S),

F

IG

. 20.

4.

Adjust the component A and component B air regulators (F and O) until both outbound gauges

(H and I) show the desired pressure, F IG . 20-21.

5.

Trigger the gun to dispense mixed material.

Adjust the Flow Rate

The dispensing flow rate for the system is controlled by the material pressure of component A and component

B.The air pressure on pump A determines the flow rate from the material outlet. Perform the steps on page

page 24 to set an initial flow rate. When the setup is

complete, adjust flow to the correct rate.

The diagram in F IG . 22 shows the inlet and outlet of the meter cylinders in relation to the direction of rod movement. The material pressure gauges will represent either inlet or outlet pressure, depending on the direction of the rod. Inlet and outlet pressures are critical to establishing meter flow rates and balanced pressures.

S

F IG . 20

F

H

O

F IG . 21

28

I

F IG . 22

Flow Rate Adjustment Example

A 20:1 fluid:air supply pump ratio with an air regulator setting at 100 psi (.7 MPa, 7 bar). The pump generates approximately 2000 psi (14 MPa, 140 bar). Fluid pressure, normal friction losses with mastic materials will use 5-15% of the force, resulting in actual stall pressure of 1700-1900 psi (13 MPa, 130 bar).

309790P

Operation

A/B Pump Relationship

As a rule of thumb, the pressures of the two components should be adjusted to as close to equal as possible under dynamic pressure. Adjust the A and B feed pressures to accomplish this. Differences on material viscosity, flow rates, hose diameter and length, dispense valve, and mixer size cause this setting to vary from application to application.

1.

Adjust the component A air regulator (O) for desired flow rate, F IG . 24.

2.

Adjust the component B air regulator (F) to balance the A and B regulators.

Solvent-flush Mixed Material (for units using mix manifold gun kits)

1.

Close the component A and component B valves on the mix chamber assembly. See F IG . 23.

2.

Ensure solvent valve is closed.

3.

Set solvent flush pump air regulator to approximately 25 psi (172 kPa, 1.7 bar) and open the air valve.

4.

Open the solvent supply valve, ensuring that the dispense valve touches a grounded metal waste container and purge until solvent comes out clean.

5.

Close solvent supply valve.

Component B Valve

8900 Proportioner with Disposable Mixer

Gun

1.

Load the material. See page 19.

2.

Set ratio. (For variable ratio models, see page 14).

3.

Install the mixer on the gun.

4.

Open the pump A and pump B air shutoff valve (S),

F IG . 24.

F IG . 24

F

O

S

5.

Trigger the gun to dispense mixed material.

6.

Adjust the component A air regulator (O) for the desired flow rate.

7.

Adjust the component B supply air regulator (F) so that component B pressure is approximately equal to the component A pressure.

8.

When you have finished dispensing, remove and dispose of the mixer, and install a red plastic cap

(part no. 551327).

F IG . 23

TI3261A

Component A Valve Solvent Valve

309790P 29

Operation

Changing Component A Drum

When the ram plate is extended fully to the bottom of the drum and the pump begins to cavitate, you need to change the drum. It is recommended that you check and refill the component B at the same time.

1.

Close the air motor shutoff valve.

2.

With the ram lever (PP) in the neutral position (F IG .

25), adjust the ram regulator (R-F IG . 26) to 0 psi.

6.

Continue to hold the drum separation air button

(PPP) just enough to keep the drum from rising with the ram plate.

7.

Follow the procedure to load material, pages 19-24.

You only need to lubricate the ram plate tire seals the first time you load material.

PP

F IG . 25

3.

Place the ram lever (PP) in the UP position, F IG . 26.

R

PP

PPP

F IG . 26

WARNING

Do not use excessive drum separation air pressure.

Make sure the drum is not damaged and the ram plate

is free to exit the drum. Read warnings, page 5.

4.

Push and hold the ram separation air button (PPP).

5.

Adjust the ram regulator (R) to approximately 10-15 psi (69-103 kPa, 0.7-1 bar) or until the ram plate begins to rise.

30 309790P

Operation

Changing Component B Pail

If you are using a ram and pump to supply component

B, the procedure to change the pail is the same as changing the Component A drum except that you use the controls on the back of the pail ram.

Pressure Relief Procedure

(For component B tank models only.)

WARNING

1.

Shut off the air supply to the tank by closing the air

inlet valve. Refer to F IG . 27.

2.

Open the drain cock fitting by turning it counterclockwise.

3.

Wait until there is no air escaping through the drain cock fitting before removing the cover or opening the fill port.

4.

Leave the drain cock fitting open until you have reinstalled the cover or fill port.

PRESSURIZED EQUIPMENT HAZARD

The pressure tanks remain pressurized until pressure is manually relieved. To reduce the risk of serious injury from pressurized fluid or accidental spray from the gun, always follow this procedure to relieve pressure in the tank at the following times:

• Before you check or service any part of the spray system

• Before you loosen or remove the pressure tank cover or fill port.

• Whenever you stop spraying.

Air inlet valve

Fill port cap

Drain cock fitting

03089C

F IG . 27

309790P 31

Operation

Filling Component B Pressure

Tank

If you are using a pressure tank to supply component B, check the tank level with a metal or plastic rod whenever the Component A drum is changed. To add component

B to the tank, follow the procedure below.

1.

Close the tank air supply shutoff valve, F IG . 28.

2.

Relieve pressure in the tank (see page 27).

3.

Open the fill port cap on top of cover.

4.

Gently roll an unopened pail of component B on the floor for several revolutions to mix it.

5.

Open the pail outlet and carefully pour the material into the tank through a funnel.

6.

Close the drain cock fitting and screw on the cap.

7.

Make sure the silica-gel in the desiccant filter is blue. If the gel is pink, replace it (part no. 106498) or bake out the moisture.

CAUTION

Do not leave the pressure tank open. Component B will crystallize if exposed to the moisture in the air.The tank cover is normally removed only for tank cleaning.

The desiccant filter is an air dryer for moisturesensitive materials, it is not included with the package.

8.

Pressurize the tank with dried air by opening the component B air shutoff valve and the pressure tank air shutoff valve.

1 Arrow points toward tank

Component B air supply valve

Dry Air Line

Tank air shutoff valve

Desiccant filter

F IG . 28

1

15:1 Component B pump ti3259ax

32 309790P

Operation

Adjust Ratio on Variable Ratio Machine

The ratio of this unit is determined partially by the difference in the area of the metering cylinders and partially by the position of the adjustable fulcrum point in the Unibar linkage assembly. With the fulcrum in the center,

(next to stop at left of center), each meter cylinder strokes 3 in. In this center position, the dispense ratio is the same as the meter cylinder ratio. The ratio is adjustable from 1:1 to 20:1 depending on the location of the fulcrum point and cylinder size. There are three machines to accommodate these ratio ranges: 1:1-4:1,

2:1-8:1, and 5:1 to 20:1. The linkage must be adjusted for each material application so that the combination linkage and meter cylinder ratio equals the desired material mix ratio by volume. The ratio is checked by weight, but the machine meters by volume. Weight ratios must be known before proceeding. If weight ratios are not known, they can be calculated using the specific gravity and known volumetric ratio of each component.

The initial linkage adjustment point can be calculated by inserting known values into the following formula. The resulting value is the distance in inches from the center of the fulcrum point to the center of the component B meter cylinder. Measure the distance from the grease fitting on top of the fulcrum to the center of the component B cylinder meter rod. For reference, see the output

charts on pages 15 through 17.

Ratio Adjustment Calculation Example:

DR = Required mix ratio by desired volume (X:1)

PR = Selected cylinder ratio (1:1, 2:1, 5:1)

LR = Linkage ratio

LD = Linkage distance (component B cylinder centerline to fulcrum center divided by LR+1)

DR

PR

= LR

Cylinder ratio 1:1-4:1 machine use PR = 1

Cylinder ratio 2:1-8:1 machine use PR = 2

Cylinder ratio 5:1-20:1 machine use PR = 5)

Example:

• Desired volumetric mix ratio (DR) = 10:1

• Measured distance from grease fitting on top of the fulcrum to the center of the component B cylinder meter rod = 14.85 in.

DR

PR

= LR

10

5

= 2:1

LD = measured distance

LR + 1

LD =

14.85 in.

2 + 1 or LD = 4.95 in.

Verify the Ratio

1.

Relieve pressure. See Pressure Relief Procedure on page 27.

2.

Remove gun and place a waste container under the component A and component B hoses.

3.

Open air valve to turn on unit.

4.

Activate the unit and using a collection container of known weight, collect a cup of component A and a proportionate amount of component B.

5.

Weigh each component carefully and subtract the weight of the container.

6.

Convert the manufacturer’s ratio to parts component

B per 100 parts Component A, by weight (2:1 =

100:50).

7.

Divide component B weight by component A weight.

8.

Multiply the result of step 7 by 100. The product is

the number of parts of component B the machine dispenses per 100 parts of Component A.

9.

Compare ratio obtained to ratio desired. Always make several ratio checks to ensure accuracy at final setup. Any air in the system will cause inaccurate ratio checks. If ratio checks are not consistent, review setup procedure.

10. If the ratio is incorrect, loosen fulcrum screw (A) and turn the ratio adjustment screw/nut (B) clockwise to decrease and counterclockwise to increase the amount of component B.

11. If the ratio is correct, tighten the fulcrum nut and reattach hoses (7) to the dispensing gun.

309790P 33

Operation

Daily Procedures

Daily Start-up Procedure

1.

Perform daily maintenance operations, including: a.

Check oil level in main air lubricator.

b.

Drain any water from filter in main air line.

c.

Tighten pump packing nuts (daily the first week, weekly thereafter).

d.

Visually inspect system for leaks.

e.

Grease zerk fittings.

2.

Turn air pressure to the unit “ON”.

3.

Check ratio on variable ratio models.

After the system is purged, do not open the dispense gun until the next system operation.

Disposable Mixer System

1.

Remove and discard the mixer.

2.

Trigger gun to ensure the outlet is clear.

3.

Turn off the main air valve.

4.

Wiper off gun nose.

5.

If material is moisture-sensitive or dries out, protect the outlet with the night cap and ISO pump oil.

General Ratio Check Procedure

Checking the ratio allows the user to take samples of the metered material to ensure the equipment is operating properly.

Steps 4 and 5 are applicable only to mix manifold

models.

4.

Open the coupled ball valves (push up).

5.

Ensure that the component A purge ball valve is closed.

6.

Place a material waste container under the gun outlet and open the dispense gun.

7.

Dispense material until well mixed material is being dispensed.

8.

The system is now ready to operate.

Daily Shut-down/Purge Procedures

Component A Purge

1.

Close the coupled ball valves (push down).

2.

Open the component A purge ball valve.

3.

Hold the dispense gun over a material waste container.

4.

Hold the dispense gun open until only component A is evident.

5.

Close the component A purge ball valve.

6.

Close the main air valve located under the meter base plate to remove air pressure from the meter.

The unit meters by volume but it is more convenient to check the ratio by weight. You must know the ratio by weight or the specific gravity of the materials to convert volumetric ratio to weight ratio.

1.

Remove the hoses from the dispense gun. Take a material sample from the outlet of these hoses.

2.

Open the air ball valves (push up) and collect a large material sample (approximately 1 pint of component A) in separate containers of known weight.

Material flowing from each hose provides a sample for ratio check. When sample is collected, turn off air supply ball valve.

3.

Weigh the component A and component B samples and subtract the weight of the collection containers.

4.

Convert the material manufacturer’s ratio to “parts component B per 100 parts component A by weight.” For example, a 2:1 ratio (component A: component B) becomes 100:50.

5.

Divide component B sample weight by component A sample weight.

6.

Multiply the result of previous step by 100. The product is the parts component B dispensed by the machine per 100 parts component A by weight.

7.

Compare the weight ratio obtained to the desired weight ratio. Repeat to obtain several successful ratio checks.

8.

Put new mix elements in the gun and reconnect the hoses to the gun.

34 309790P

Operation

9.

Ration check is complete and the unit is ready for operation

Ratio Check Example

Conversion Formula:

Parts by Volume (PBV) to Parts by Weight (PBW)

PBV component B

PBV component A

X

Specific gravity component B

Specific gravity component A

X

= 100:Parts component B by weight

Ratio Check Example component B sample weight LESS container weight component A sample weight LESS container weight

X 100 =

X 100 = PRODUCT

X

PRODUCT = Parts component B per 100 parts component A

• Manufacture’s specified weight ratio = 4:1 or 100:25.

• Weight of component A in ratio check is 245 grams.

• Weight of component B in ratio check is 61.2 grams.

• 61.2 divided by 245 equals .2497 (61.2 / 245 = .2497).

Three ratio checks are recommended to ensure accuracy at final setup. The presence of any air (visible or not visible) in the material or system will cause inaccurate ratio checks. If the ratio check cannot be made with repetitive accuracy, review air bleed procedures.

Some materials contain substantial amounts of entrained air due to manufacturing, transportation, system setup, or drum change. Air must be removed by de-gassing, recirculation, or self removal over time, before accurate metering can be accomplished.

309790P 35

Troubleshooting

Troubleshooting

8900 Proportioner Operating

Pressures

There are four fluid pressure gauges on a typical 8900

Proportioner system. They are mounted on:

• Component A inlet block

• Component B inlet block

• Component A outlet block

• Component B outlet block

What the fluid gauges tell you

Inlet Gauge

The pump A and pump B inlet pressure gauge shows whether there is sufficient material supply to reliably feed each metering pump during its intake stroke.These double- acting pumps dispense and load fluid on both strokes.

The pump A and pump B supply air pressure should be set high enough to maintain reliable pump feed pressures but no higher than necessary. If gauge pressure is not consistently steady, increase fluid pressure.

Outlet Gauge

The pump A and pump B outlet gauge displays one of two conditions, stalled and running.

• Stalled: With the pump air valve on and the gun closed, the gauge will show full stall pressure. This pressure is the fluid to air pressure ratio of the pump assembly, times the air pressure from the main regulator, minus the friction loss of the motor and pump assembly.

The fluid to air pressure ratio changes with different motors, different supply pumps, and different ratio settings.

• Running: When running, the gauge reads the flow-induced pressure drop between the gauge and the gun outlet. The motor power is used up by the time the fluid exits the gun. The pressure drop is a measure of friction loss caused by hoses, the 8900

Proportioner, fittings, mixers, and gun.

The difference in the gauge reading between the stall condition and running is the amount of dynamic friction loss from the pump assembly, plus the flow-induced pressure drop from the pump lower to the pressure gauge.

Viscosity, temperature, flow rate, and gun setup can affect the amount of gauge drop when the trigger is pulled. On a typical manual gun system, the gauge drops 100-400 psi (0.7-2.8 MPa, 7-28 bar).

Component B Pump Outlet Gauge

The component B pump gauge shows line pressure, but the component B outlet pressure is generated primarily as a reaction to component A pressure at the mix chamber.

For materials running at greater than 1:1 ratio, component B cannot open the check (injector) valve until its pressure equals the component A pressure at the check valve. Hoses and injector restriction are chosen to naturally balance the pressure drop while running and match the component B pressure in the line when stalled.

Changeovers

When the pumps change direction there is a momentary change in gauges. In general, the gauges will drop

5-15%, then return. However, many factors affect the actual fluctuation, such as pump selection, fluid characteristics, flow rate, temperature, and length of hoses.

Check valves near the pump outlets isolate the hoses to let them serve as momentary surge chambers. This is why flow from the gun is smooth during changeover.

Abnormal Readings

Since so many factors affect gauge readings, it is important to know what is normal. Note how your gauges read when the machine is setup and running a good mix with no soft spots. What are the stall pressures and what are the running pressures for a given inbound air pressure?

How much drop is there on changeover?

If something goes wrong, a change on the gauges can indicate what the problem is. Note those changes and work through the troubleshooting guide, beginning on

page 39.

36 309790P

Troubleshooting

Air Supply Troubleshooting Chart

Problem Cause Solution

Abnormal pressure loss on air motor pressure regulator gauge during both changeovers.

Abnormal A and B pump outlet pressure loss during both changeovers.

Air line restriction due to quick-disconnect pin fitting.

Air supply line ID to each feed pump is too small.

Reduced flow rate.

Off-ratio material.

Undersized air compressor.

Remove quick-disconnect from the air line and replace it with bleed-type air shutoff valve.

Replace with minimum 3/4 in. (19 mm) ID hose.

Replace with properly sized air compressor.

During normal operating conditions, the feed pump (A and B) air motors are filled with air almost instantaneously on both changeovers.

However, if the feed pump air supply is restricted, it can take significantly longer for air to fill the air motor. To check for this, observe the gauge on the air motor pressure regulator during both changeovers:

• At the end of each stroke the air pressure will drop abnormally as the air motor begins to fill.

• At the same time the A and B pump outlet pressures will drop abnormally due to the feed pump’s respective air motor’s reduced pressure.

• The decrease in the pump outlet pressures causes the flow rate at the dispense gun to be reduced.

• Once the air motor has filled with air, all air pressures and flow rates will return to normal until the end of the next stroke.

• The decreased pump outlet pressure may affect the feed pumps’ checking action, and thus mix ratio, resulting in the dispense of what appears to be poorly mixed material.

• Changing air pressure changes the compression of the component A hose and material. This causes an off ratio condition until pressures stabilize. Equipment air supply pressure must always stay above the motor regulator setpoint.

309790P 37

Troubleshooting

Pump Troubleshooting

Overview

Pump Cavitation

Under normal operation, when the feed pump pressures are balanced, component A and component B outlet pressures are consistent.

Some up or down adjustments in feed pressures will be necessary to keep the pumps’ outlet pressures balanced. This is due to viscosity differences in the two materials, volumetric ratio, and required flow rate.

Because of the viscosity difference between the two materials, most of the balancing effect comes from adjusting the component A pressure. For ratios higher than 1:1, the component B pressure should be set only as high as necessary to avoid cavitation at the desired flow rate. For 1:1 ratio there is equal balancing from component A and component B pressure.

If either the A or B pump does not completely fill with material on intake, the failing pump’s material output is interrupted at the beginning of the next stroke. This is referred to as cavitation.

Pump A cavitation is detected by observing the inlet pressure gauges on pump A and pump B immediately after changeover. When cavitation occurs, the proportioner pump outlet pressure gauge drops and the pump

A outlet pressure gauge shows an increase in pressure, as described previously.

B pump cavitation is detected by observing the B pump inlet pressure gauge immediately after pump top changeover. When cavitation occurs, the B pump outlet pressure gauge drops.

If the amount of cavitation is moderate, the pressure gauges return to their normal readings at some point during the downstroke of the failing pump.

During pump A cavitation, the pressure drop may cause a noticeable reduction in flow rate at the dispense gun.

Additionally, the interruption in the pump A material output may cause component B-rich material to dispense, which may appear as poorly mixed material.

During B pump cavitation, the interruption in the B pump material output may cause component A- rich material to dispense, which may appear as poorly mixed material.

Pump Failure to Seal

Under normal operation, the output of the component A and component B pumps depends upon proper sealing of their internal packings.

If packings fail to seal properly, the pump material output, and thus the output pressure, is reduced. Depending on the location of the failure, the pressure reduction may occur on the pump upstroke, downstroke, or both strokes.

Component B Pressure Relief Valve

The proportioner includes a spring-loaded, overpressure relief valve, which bypasses component B back to the supply when pressures exceed 3400 psi (23 MPa,

234 bar).

38 309790P

Troubleshooting

Troubleshooting Guide: Feed pumps

Problem

Erratic feed pump speed.

Material leaking from top of pump

Feed pump fails to cycle

Cause

Pump cavitation.

Pumping too fast.

Improper pump loading.

Pump lower not performing.

Loose packing nut.

Worn throat seals.

Air supply off.

Air pressure too low.

Stalled air motor.

Lack of air pressure.

Ram fails to move up and down

Material leaking past follower plate seal (small amount of leakage is normal)

Ram failure.

Too much ram pressure.

Worn wiper seals.

Dented container.

Solution

Bleed air from pump.

Turn down air pressure regulator.

Increase ram down pressure

Ram valve not in down position.

Rebuild pump

Retighten.

Rebuild pump, replace seals.

Check air valves/line pressure. Turn on if required.

Increase air pressure on respective feed pump air regulator.

Motor icing (warm up).

Check air filter and lubrication.

Turn on or increase air supply pressure to ram.

Check and rebuild.

Reduce ram down pressure on ram air pressure.

Replace.

Straighten or replace container.

309790P 39

Troubleshooting

Troubleshooting Guide: 8900 Proportioner


Inconsistent material mix

Meter pressures never change

Meter will not shift at the end of the stroke.

Meter will not move

Material inlet pressures are not set correctly. Erratic feed pump.

Mix elements not assembled correctly or need to be replaced.

Cylinder cups are bypassing material.

Material outlet hoses are not sized correctly (pressures not balanced).

Material ball valves are bypassing.

Insufficient air supply to material supply pumps.

Follow flow rate procedures and ram feed pump troubleshooting guide.

Fix or replace.

Replace cylinder cups.

Call Graco Tech Service -

(800) 543-0339

Rebuild/replace.

Verify consistent air supply.

Purge valve open (if applicable).

Broken material gauge(s).

Limit valve not working correctly.

No material inlet pressure.

No air supply to limit valve.

Material inlet pressure not high enough to drive meter.

Close during operation.

Replace.

Rebuild/replace, see page 45.

Verify.

Verify.

Verify low pressure on the gauges before increasing.

4-way ball valve orientation incorrect. Check, fix.

Dispense valve closed.

Open.

Blockage in material hose.

Blockage in meter assembly.

Depressurize system and repair.

Depressurize system and repair.

Material leaking from meter end caps Worn seals.

End caps loose.

Meters not balanced

Meter outlet pressure too high, metering inaccurate, decreased flow rate, non-uniform mix (streaking)

Replace.

Hand tighten with wrench provided.

Improper operation of supply pumps. Check for proper operation of mate-

Inadequate material supply to rial supply pumps. Each should have pumps.

adequate material supply. Reasonably constant and balanced meter inlet and outlet pressures indicate proper pump function. If flow rate is increased by increasing A pump pressure, increase B pump pressure proportionally to balance meter inlet and outlet pressures.

Curing material in the mixer or blockage of either mixer inlet port (check valves/injector valves plugged).

Clear blockage.

Incorrect ratio check and reduced flow rate

Inaccurate metering

Material may be bypassing rather than flowing through the meter.

Air in the material or trapped in the pumping and metering components.

Check for leakage in meter seals and cups.

Bleed the air from the pump.

40 309790P

Troubleshooting

Troubleshooting Guide: Manifold/Mixer


Poor mix quality.

Dirty mixer.

Inadequate mixing.

Disassemble Tri-Core mixer, clean housing and end caps, and replace mix elements.

Add mixer with more elements or larger ID mixer.

Dirty mixer and gun.

Replace flex mixer or clean Tri-Core mixer and gun.

Tri-core mixer assembled improperly. Reassemble with scribe lines on end caps aligned.

Clean or replace injector.

Fouled or plugged component B injector.

Cavitation due to ram air control valve not in DOWN position.

Place control valve in DOWN position.

Reduced flow rate.

Poor purge quality.

Abnormally high B pump outlet pressures.

Abnormally high pump A outlet pressures.

Cavitation due to low ram pressure.

Increase to required operating pressure.

Dirty mixer.

Disassemble Tri-Core mixer, clean housing and end caps, and replace mix elements.

Dirty mixer and gun.

Replace flex mixer or clean Tri-core mixer and gun.

Leaking component B shutoff valve.

Repair or replace valve.

Leaking component B shutoff valve.

Repair or replace valve. May require solvent flush after valve replacement.

Fouled or plugged component B injector.

Clean or replace injector.

Feed pressure too high.

Restriction in gun or hose, plugged check valve.

Reduce feed pressure.

Clean out gun.

Inspect for cured material in check valve.

Soft spots or color change relating to changeovers.

Pressures are out of balance.

Adjust pressure settings on A and B supply pumps to balance outbound ram pressure too low on feed pump.

309790P 41

Troubleshooting

Component B Injector

In most dispense systems, an injector is included in the component B fluid line. This injector adds back pressure to the system and provides the necessary pressure balance between component A and component B to achieve the proper ratio and mix.

If the injector becomes fouled with mixed material, the pressure indicated on the B pump outlet gauge will increase and upset the pressure balance, resulting in the dispense of poorly mixed material.

If the injector becomes completely plugged, only component A is dispensed from the gun and the B pump outlet pressure will increase until the relief valve discharges.

If the injector valve sticks, it can react sluggishly causing soft spots after valve triggering or changeover.

Keep the injector clean. Inspect the housing tip and needle end for dents or scratches. Lapping the needle to the housing with automotive lapping compound will recondition the seat/needle. When reassembling the injector, tighten the nut 2-2.5 turns after the slack is taken up.

It is good practice to have a clean injector on hand. A fouled injector can then be replaced quickly, and thoroughly cleaned and held for future use.

Preventive Maintenance

1.

Air supply: Oil level in main air line lubricator should be checked daily and refilled when necessary with

SAE 10W non-detergent oil. Adjust to dispense 1 drop per minute during operation.

Main air line filter should be drained as required.

Excessive amounts of water in the system will reduce machine performance.

2.

Housekeeping: Spilled materials on any part of the equipment should be cleaned up promptly. Your system is precision equipment and should be maintained as such. A light coating of petroleum jelly on components will often prevent spilled material from sticking to equipment.

3.

Pumps: Pump packing should be tightened daily the first week of operation and weekly thereafter.

4.

When using Throat Seal Lubricant (TSL) or ISO oil, the lubricant should be maintained at an adequate level in the pump packing reservoir. These lubricants prevent material from sticking to pump rods, extends packing life, and protects material from contamination from the atmosphere.

Use ISO oil when dispensing moisture-sensitive materials.

Meter: Maintain TSL or ISO oil in reservoir if used; grease zerk fitting. Clean up spills as soon as possible to prevent damage to the meter.

5.

Mixer: With most materials, frequent use of equipment is all that is needed to prevent internal curing.

Some materials have a tendency to cure slowly on the walls of the mixing chamber. Experience will dictate how often the mixer or mixer elements should be thoroughly cleaned or replaced.

6.

O-rings/Seals: O-rings and seals will be damaged if soaked in solvents. When reusing, wipe with solvent and dry immediately.

42 309790P

Service and Repair

Service and Repair

Repair the Cylinder (Fixed Ratio)

• Relieve pressure throughout the 8900 Proportioner assembly. Follow the pressure relief

procedure on page 31.

• Reference numbers shown in parentheses in

Service and Repair procedures refer to references in figures and parts lists.

8.

Remove packing nut (103) from opposite cylinder end cap (106) and remove throat packings and glands (110, 111, 112).

9.

Remove piston assembly (106, 107) from rods (101,

102).

10. Replace V packings and glands on both ends with new ones and reassemble in reverse order of disassembly.

11. Replace cylinder end o-rings (109) on each cylinder end cap. Apply grease to each to help hold o-ring into end cap.

12. Push piston assembly through cylinder block (113).

Use grease generously during reassembly.

17

30

116

30 10, 11

113

F IG . 29: Fixed Ratio 8900

1.

Disconnect hose (17) on cylinder end manifold, F IG .

29.

2.

Remove guard tube (116).

3.

Loosen and remove 4 locknuts (30).

4.

Loosen nut (10) on coupling (11) and disconnect pump rod from coupling.

If the entire cylinder needs to be removed and serviced at another location, loosen and remove screws (49). Then loosen union (9) to remove the

cylinder assembly from unit. See page 49.

13. Replace o-rings (114) on each packing nut and screw, then screw packing nut back into cylinder end caps. Hand tighten until firmly seated on packings, then wrench tighten 1/4 turn.

14. Push cylinder assembly back together.

15. Complete reassembly of the cylinder in reverse order of disassembly.

5.

Pull on cylinder block (113), F IG . 31. Cylinder should come apart.

6.

Remove rod and piston assembly from cylinder.

7.

Remove packing nut (115) from cylinder block (113) and remove throat packings and glands (110, 111,

112).

F IG . 30: Variable Ratio 8900

309790P 43

Service and Repair

17

30

17

5

9

104 109

10

11

TI2761A

114 101 116

F IG . 31

44

103 112 110 111 102 107 106 113 115 246558

309790P

Replace Air Valve

F IG . 32

303 304 305

Service and Repair

1.

Unscrew 2 socket head cap screws (311), F IG . 33.

2.

Pull complete air valve assembly off cylinder and connecting rod assembly.

3.

Remove retaining ring and plate off end and pull rod through.

4.

Remove retaining ring off appropriate air valve

(303), pull out valve (304) and replace with new valve.

5.

Reassemble in reverse order of disassembly. Make sure not to remove spacer (305) during disassembly. This spacer sets correct alignment of valves.

6.

Reattach air valve assembly to the 8900 cylinder block and connecting rod assembly.

311

F IG . 33

309790P 45

Disassemble Fluid Valve

Disassemble Fluid Valve

F IG . 34

1.

Relieve pressure and turn off feed supply units.

Close air valve.

2.

Remove valve assembly from 8900 cylinder. Take off hose (17), union (9), fitting in (5), fitting out (5).

See F IG . 31.

3.

Remove 4 socket head cap screws (415, F IG . 35.

4.

Pull off end cap (413).

5.

Pull out ball passage (411) with backup ring (409), packing o-ring (410), and bushing (408).

6.

Remove packing assemblies consisting of seal

(402), o-ring (403), bushing (404), o-rings (406,

407), and connector (405).

7.

4-way valve must be installed so that flow paths marked on shaft (see illustration below) are 90° out of phase with each other. Stamped indicators on shaft end of valves show material flow paths.The

8900 Proportioner will not cycle if the valves are not in proper phase with each other.

When reassembling, apply grease to all o-rings and bearings.

402

403

404

Enlarged detail of flow path marking

408

409

410

407

406

405

411

413

415

F IG . 35

46 309790P

Disassemble Fluid Valve

309790P 47

Parts

Parts

8900 Proportioner, Fixed Ratio

Item 7 Item 14

Part Number

Fixed

Ratio

1:1

2:1

2.5:1

4:1

5:1

9:1

10:1

Assembly

No.

570371

570372

570373

570374

570375

246557

570376

1

1

1

1

1

Quantity

2

1

1

1

1

1

1

1

Ref.

No.

Part No. Description

23

24

25

26

19

20

21

22

27

28

30

31

10

11

12

13

14

1

3

4

C24016 ARM, trip

187877 TUBE, gauge

102814 GAUGE, fluid pressure

5

6

7

624545 T-FITTING; 3/4 npt(m) x 1/4 npt(f)

157785 UNION, swivel; 3/4 nps x 3/4 npt

8

CYLINDER; see table above; see

page 52

C19411 CONNECTOR; 3/8 npt x 3/8 tube

9 C24042 UNION; includes 9a

9a* 105802 • O-RING; fluoroelastomer

17

110343 SCREW; 1/2-13 UNC x 1.75 in.

C23016 COUPLING

C24013 SPACER

C24053 COUPLING

CYLINDER; see table above; see

page 52

552272 HOSE; 3/4 npt, 4000 psi (28 MPa,

276 bar)

100214 LOCKWASHER

C19829 SCREW; 5/16-18 x 2.5 in.

111303 NUT; hex

C24052 BRACKET, valve mounting

109212 SCREW; 3/8-24 x 3/4 in.

C24046 ACTUATOR, pneumatic

C24029 VALVE, 4-way

C24014 VALVE, limit

598729 ELBOW, 90°; 1/4 npt x 1/4 in. tube

590385 TUBE, nylon; 0.375 OD; 6 ft

101926 LOCKNUT; 1/2-20 NF

C29034 WRENCH, spanner

Qty.

4

4

1

1

2

4

2

4

2

1

1

1

2

2

2

1

8

1

4

2

4

4

8

1

1

*

48

32

38

39

40

41

42

43

44

48

49

50

51

52

57

Ref.

No.

45

47


156172 FITTING, swivel; 3/4 nps x 3/4 npt

C03190 RING

C23269 CHAIN

C24140 MANIFOLD, lube

949666 AIR CONTROL; see page 53

C30021 U-BOLT; 3/8-16 UNC

237112 VALVE, relief

113344 UNION, swivel; 1/2-14 npt x 3/4 npsm

113187 CONNECTOR, tube, 1/2 OD x

1/2 npt

061134 HOSE, nylon; 1/2 in. OD, 1.4 MPa,

(14 bar, 200 psi), 6’

105209 SCREW; 10-32 UNF x 7/8 in.

100101 SCREW; 3/8-16 UNC x 1 in.

100131 NUT; 3/8-16 UNC

100133 WASHER, lock; 7/16 in.

965785 BASE

100840 ELBOW; 1/4-18 npt

2

10

6

6

1

1

Qty.

2

1

1

1

2

3

2

1

1

1

*EPDM replacement part available in kit 289401.

42

42

32

3

4

5

6

52

26

1

TI2763A

4

5

44

309790P

Parts

309790P

13

17

57

45, 46, 47

9

2

30

41

7

49

43, 44

22

23, 24

22

17

25

19, 20, 21

9

14

10

11

12

TI2761A

27 28

27

28

8

26

27

27 28

TI2762

49, 50, 51

40, 48

49

Parts

8900 Proportioner, Variable Ratio

Variable

Ratio

1:1 - 4:1

2:1 - 8:1

5:1 - 20:1

Assembly

No.

570377

570378

570380

2

1

1

Item 1

Quantity

Item 2

Part Number

1

1

Ref.

No. Part No. Description Qty.

1

2

4

6

7

CYLINDER; see table above and

page 52

CYLINDER; see table above and

page 52

624545 FITTING, TEE 3/4m run X 1/4f

157785 FITTING, union, swivel

102814 GAUGE, pressure, fluid

8 156172 FITTING, union, swivel 5

9 552272 HOSE, PTFE 3/4-18” 5000 psi npt(m) 2

12 C23016 COUPLING, pair 2

13 C19854 SCREW, cap, socket head

14 C24016 ARM, trip

15 C24422 ROD, tie

4

4

4

2

1

8

16 101926 NUT, locking, metallic

17 C23280 8841-4-A, beam assembly

18 C24420 SCREW, ratio adjusting

19 C24419 PLUNGER

20 C29031 BAR, uni

21 C29023 ASSEMBLY, fulcrum

22 C29037 STOP, unibar

16

1

1

1

2

2

1


24 C24046 ACTUATOR, pneumatic

25 C07086 COUPLER, long

26 C24418 BRACKET, 3/4 valve mounting

27 C24029 VALVE, 4-way

29 109212 SCREW, cap, socket head


31 111303 NUT, hex

32 100214 WASHER, lock

33 C23276 MONITOR, scale


35 100018 WASHER, lock, spring

36 100321 NUT

38 C24014 VALVE, limit

39* C24042 FITTING, union, assembly

40 C24417 STUD

43 100847 FITTING, lubrication

44 C24442 PLATE, designation

45 C29034 TOOL, spanner wrench

46 C23269 CHAIN

2

2

1

1

2

3

4

1

1

1

2

1

4

4

2

8

2

2

2

1

Ref.

No. Part No. Description Qty.

47 C03190 RING

49 100840 ELBOW, street

53 C29043 BUSHING, ball

54 160327 FITTING, union, adapter, 90 degree

55 157191 FITTING, adapter

56 237112 VALVE, relief

57 156022 ADAPTER

58 205439 COUPLING, hose

59 061134 HOSE, nylon

60 C24140 MANIFOLD, lubrication

61 105209 SCREW, cap, socket head

62

949666 AIR CONTROL; see page 53

63 100004 SCREW, cap, hex head

64 100131 NUT, full hex


66 965785 BASE, weld mount 8900 VR

67 C30021 BOLT, u 2

68 626814 SPACER, .75 od x .45 id x .50 lg alum 8

72 598729 FITTING, elbow, male, 90 degree

73 590385 TUBE, 3/8 in. OD nylon 3.6 ft

2

*

74 C19413 FITTING, tube

75 513754 COLLAR, shaft 1.250 cs split

79 113344 UNION, swivel

2

2

1

6

1

8

6

2

1

6

1

1

1

1

1

2

2

2

4


66

72, 73, 74

60, 61

62, 63, 64, 65

Top View

67

50 309790P

14

43

53, 19

44

12

13

27

30, 31, 32

7, 49

54

9

1

75

33, 34 20 21

12, 35, 36

75

22

23, 35

17

18

16

15

13

24, 25, 29, 25

26

27

4

38

6 55

56

55

570378 and 570380 2

570377 1

54

54

16

7

9

57

58

59

6

4

39

40

Parts

309790P 51

Parts

Cylinder Assemblies

(ref. nos. 7 and 14 FR, 1 and 2 VR)

Part No. 246558

Model 246557 only

Part No. 570366

Models 570373 and 570374 only

Part No. 570367

Models 570372, 570375, and 570377 only

Part No. 570369

Models 570371 and 570376 only

Part No. C24145

Models 570371,570372, 570374, 246557,and 570376

Ref.

No.


101 C24054 SHAFT, piston, outer

102 C24055 SHAFT, piston, inner

103 C24022 NUT, packing

104 C24026 BLOCK, cylinder, inside

105 15C180 CYLINDER, 111; 246558 only

C23171 CYLINDER, 250; 570366 only

C23200 CYLINDER, 500; 570367 only

C23137 CYLINDER, 100; 570369 only

C23136 CYLINDER; 1000; C24145 only

Qty.

1

1

1

1

1

Ref.

No.


106 15C181 SPACER; 246558 only

C23431 SPACER, 570366 only

C23460 SPACER, 570367 only

C23398 SPACER; 570369 only

C05031 SPACER; C24145 only

107 15C182 PACKING, cup; 246558 only

C23318 PACKING, cup; 570366 only



C05032 PACKING, cup; C24145 only

108 15C183 RING, backup; 246558 only

C23547 RING, backup; 570366 only


C05029 RING, backup; C24145 only


109* C20278 O-RING; fluoroelastomer

110 C21002 V-PACKING; PTFE

111 C36244 GLAND, male

112 C36246 GLAND, female

113 C24023 BLOCK, cylinder, outside

114* 188554 O-RING, fluoroelastomer

115 C57617 NUT, packing

116 C57618 TUBE, guard

117 179788 LABEL, warning

*EPDM replacement part available in kit 289402

Qty.

1

2

2

2

10

2

2

1

2

1

1

1

114 104 109 105 111 110 112 114 101

52

103 112 110 111 102 108 107 106 109 113 115

105

116 117

C24145

108 107 106

309790P

Limit Valve

(ref. no. 26 FR, 38 VR)

Part No. C24014

Ref.

No.


301 C20439 RING, retaining ext

302 C24008 WASHER

303 C20407 RING, retainer

304 C22064 VALVE

305 C24007 SPACER

306 C24051 MANIFOLD

307 100079 WASHER, lock, spring

Qty.

1

2

2

1

4

2

2

Ref.

No.

Part No. Description Qty.

308 C19977 SCREW, cap

309 C24012 VALVE, 4-way

310 C20852 FITTING, plug, 10-32

311 C19835 SCREW, cap socket head

312 C24017 ROD, trip, valve

313 C24009 SPRING, compression

314 C20068 PIN, spring

315 C24018 COLLAR, stop

316 C24019 INDICATOR, scale 1

317 C19146 SCREW, mach, slotted round head 2

318 C24020 COLLAR, clamp

319 C19264 PLUG, pipe plug 1/4 in.

320 C24016 ARM, trip 1

1

3

2

2

1

2

5

2

2

1

Parts

302

301

303 304 305 306

319 319

307

308

309

310 311 312 313 320

316

317

314

315

318

309790P 53

Parts

Air Control

(ref. no. 41 FR, 62 VR)

Part No. 949666

Ref.

No.


201 626086 BRACKET

202 624225 AIR MANIFOLD

203 157191 ADAPTER; 3

204 206197 AIR REGULATOR; 1/2 x 3/4 npt 2

1

1

205

206

100840 ELBOW; 1/4-18 npt

160430 GAUGE, air pressure

207 1554701 UNION, 90° swivel; 1/2-14 npsm x

1/4-14 npt

208 105170 SCREW; 1/4-20 UNC x 2 in.

2

2

3

209

210

211

100015 NUT; 1/4-20 UNC

100016 WASHER, lock

110225 VALVE, 2-way, vented; 1/2-14 npt

3

5

5

2

Ref.

No.


212 103475 TEE; 1/2 npt

213 100122 NIPPLE; 1/2-14 npt

214 214848 LUBRICATOR, air line

215 106149 FILTER, air; 1/2 npt

216 172124 NIPPLE; 1/2-14 x 3/8-18 npt

219 ▲ 551206 WARNING LABEL

220

▲

551207 INSTRUCTION LABEL

221 158990 AIR MANIFOLD

222 158491 NIPPLE; 1/2-14 npt

223 155495 UNION, 90° swivel; 1/4 npsm x 3/8 npt

224 162453 NIPPLE; 1/4 npsm x 1/4 npt

225 101748 PLUG; 3/8-18 npt

226 100361 PLUG; 1/2-14 npt

227 C19411 CONNECTOR; 3/8 tube x 3/8 npt

228 106285 U-BOLT; 1/4-20 UNC

229 C19394 ELBOW, 90°; 3/8 tube x 3/8 npt

1

1

2

2

2

1

Qty.

1

1

1

1

1

2

1

1

1

2

221

226

209

210

225

208

220

219

223

227

223

222

201

229

202

54

203

(behind)

206

204

205

207

212

213

203

211

224

213

214

216

225

215

222 211

210

228

210

228

207

309790P

4-Way Valve

(ref. no. 25 FR, 27 VR)

Part No. C24029

Ref.

No.


401 C24030 BODY, valve

402 C24031 SEAL

403* C24036 PACKING, o-ring

404 C24033 BUSHING

405 C24034 FITTING, connector



Parts

Qty.

4

4

4

4

1

4

4

Ref.

No.


408 C24037 BUSHING

409 C24038 RING, backup

410* 103611 PACKING, o-ring

411 C07068 BALL, passage


413 C24041 CAP, end




Qty.

4

4

1

1

2

1

2

4

401 402 403 404

405

406 407

414

415

411

409

410

409

408

412

413

408

409

407 406 405

410

409

309790P 55

Parts

Pump Feed Module Selection for

Component A or Component B

20:1 President on 5 Gallon Ram

(See Graco Manuals 308026 and 306838)

Module No. 965571

Ref.

No.


47

48

49

51

42

43

44

45

27

35

36

37

4

13

22

24

52

53

54

237207 PUMP, President, 20:1

222812 PLATE, wiper, 5 gallon

102556 RIVET, blind

156823 UNION, swivel

184147 SHIELD, 5 gallon ram

113269 VALVE, ball, vented, .500

155865 UNION, adapter

237569 WIRE, assy, 25 ft

156971 NIPPLE, short

104984 TEE, pipe

113286 VALVE, safety

160701 ELBOW, street

237562 SUPPORT, pump

113208 FITTING, tube

113896 VALVE, control

104765 PLUG, pipe headless

110318 REGULATOR, air, 1/4 in.npt

110319 GAUGE, pressure, air, 1/8 in. npt

160107 NUT, cap

Qty.

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

4

1

1

1

76

77

79

80

72

73

74

75

67

68

70

71

59

63

65

66

55

56

57

58

Ref.

No.


101533 WASHER, spring lock

190265 SPACER

238925 PISTON, ram, 5 gallon

166552 CAP, cylinder

206726 BASE, and cylinder

054123 TUBE, nylon 3.7 ft

190256 CLAMP, support

100680 SCREW, cap, hex head

101566 NUT, lock

100023 WASHER, flat

114320 FITTING, connector, 1/8 npt(f)

115901 TRIM, edge, protection

160327 UNION, adapter, 90°

235497 VALVE, check

100896 FITTING, bushing, pipe

H45010 HOSE, fluid; nylon; 1/2 in. (13 mm)

ID; 1/2 npsm(fbe); 10 ft (3.05 m) long

214656 HOSE, coupled, 61209, 10 ft

109126 HOSE coupled, 10 ft

155470 UNION, swivel, 90°

158491 FITTING, nipple

Qty.

2

1

2

1

1

2

4

4

2

4

1

*

1

1

1

1

1

2

1

1

56 309790P

49

48

63

53

45

77

24

52

5

42

60

43

44

51

54

55

4

56

67

47

57

59

22

72, 73, 74, 80, 75

76, 36

48

65

71

35

Parts

79

80

37

68

66

65

70

06537

13

309790P 57

Parts

34:1 Senator on 5 Gallon Ram


Module No. 965597

Ref.

No.


24

25

26

29

15

17

22

23

30

34

1

2

3

4

7

10

12

222769 PUMP, senator (4.5 cm)


100133 WASHER, lock


101154 PIN, driv-lok

102556 RIVET, blind


184150 SPACER, rod, elevator

184147 SHIELD, 5 gallon ram






160107 NUT, cap


110318 REGULATOR, air, 1/4 in. npt

Qty.

1

1

1

2

*

1

1

1

1

1

4

1

1

1

1

4

4

Ref.

No.


53

55

56

57

46

47

50

52

35

36

37

38

39

40

45

58

59

60


104765 PLUG, pipe, headless


238925 PISTON, ram, 5 gal.


110225 VALVE, ball, vented

237569 WIRE, assy, 25 in.

180916 MANIFOLD, adapter


114320 FITTING, connector, 1/8 npt(f)



235497 VALVE, check


215238 HOSE, coupled, 61220

214656 HOSE, coupled, 61209, 10 in.

109126 HOSE, coupled, 10 in.

156684 UNION, adapter, swivel

Qty.

1

1

2

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

58 309790P

26

35

34

53

59

25

30

30

25

22

15

37

36

53

Parts

23,29

39

30

50

10

51

4

58

40

60 47

46

52

57

05687x

1

2

3

52

55

55

52

309790P 59

Parts

23:1 Monark on 5 Gallon Ram


Module No. 570142

36

37

41

42

28

29

34

35

43

44

45

47

49

1

2

4

11

19

25

27

Ref.

No.


184147 SHIELD, 5 gallon ram (not shown) 1

206994 FLUID, TSL 8 oz bottle (not shown) 1

222782 PUMP, Monark 1




113269 VALVE, ball, vented .500

1

1

1

1




104984 TEE, pipe



238925 PISTON, ram, 5 gallon


160107 NUT, cap


190265 SPACER



1

*

1

1

1

1

1

1

1

1

1

1

1

64

65

66

67

59

60

61

62

68

69

50

51

52

53

54

55

58

Ref.

No.

70

71

73



104765 PLUG, pipe, headless





190256 CLAMP, support


101566 NUT, lock

159239 FITTING, nipple, pipe, reducing

100023 WASHER, flat

114320 FITTING, connector 1/8 npt(f)




235497 VALVE, check



214656 HOSE, coupled, 61209, 10 ft

109126 HOSE, coupled, 10 ft


Qty.

3

2

1

2

1

1

1

4

4

4

2

2

1

1

1

1

1

1

1

2

60 309790P

52

71

49

50

19

37

55

47

47

67

47

41

53

54

55

65

43

51

45

34

35

36

44

25

42

70

28

27

61

60

69

73

66

68

29

48

64

47

67

66

4

58

62

59

11

05689C

Parts

309790P 61

Parts

20:1 President on 55 Gallon Ram


Module No. 570114

Ref.

No.


19

20

22

23

11

12

16

18

1

2

3

5

7

9

10

29

31

32

36

24

25

26

28

37

38

215335 BASE, ram

222768 PUMP, President (4.5 cm)

276025 CLAMP

206537 CLAMP, drum

184140 PLATE, mounting


104984 TEE, pipe



102637 SCREW, cap


100122 NIPPLE, close

100133 WASHER, lock

100672 SCREW, set

100132 WASHER, flat

100464 SCREW, lag


101535 NUT, full hex

189559 CAP, end







Qty.

4

4

1

4

4

4

1

1

1

1

1

1

1

1

4

1

1

1

1

1

1

4

2

4

4

Ref.

No.


79

80

81

82

75

76

77

78

83

84

85

87

56

58

64

69

50

51

52

55

40

41

45

46

47

48

49





111162 FITTING, elbow

167652 ROD, tie ram

238928 PISTON, 55 gallon ram

114363 VALVE, ball, fluid

167646 BEAM, ram


238929 PLATE, 55 gallon ram

109495 PACKING, o-ring

208048 HOSE, coupled 61089

100403 PLUG, pipe



100016 WASHER, lock

114243 VALVE, check


113915 FITTING, union

158212 BUSHING

235497 VALVE, check

160327 UNION, adapter 90


214651 HOSE, coupled, 61209, 17 ft

109126 HOSE, coupled, 72 in.

184037 FITTING, outlet (6 cm)

Qty.

1

2

1

1

1

1

2

2

1

1

1

1

1

1

1

1

2

1

1

1

2

2

*

1

1

1

2

62 309790P

Parts

309790P

1

54

25, 26

53

49

51

52

48

20, 18

7

45

22

21

78

58

77

80

84

40

41

22

13

3

16

81 82

2

37

85

36

29

12

16

9

82

69

10

52

46

58

83

56

32

50

55

0717E

63

Parts

34:1 Senator on 55 Gallon Ram

(See Graco Manual 308027)

Module No. 965572

3

4

5

6

7

9

10

11

12

15

Ref.

No.


235497 VALVE, check



214651 HOSE, coupled, 61209, 17 ft


222769 PUMP, Senator (4.5 cm) 1

241253 RAM, pneumatic, EPDM, 55 gallon 1

1

1

1

2

1

276025 CLAMP

102637 SCREW, cap


4

4

1

Ref.

No.


20

21

22

23

25

30

31

34

35

36



100133 WASHER, lock


114363 VALVE, ball

158256 SWIVEL, union assembly


206537 CLAMP, drum


158212 BUSHING

Qty.

1

1

1

1

1

4

4

1

1

1

6

36

10

12

11

35

7

3

31

15

21

22

9

30

4

5

4

20

0717E

64 309790P

Parts

31:1 Bulldog on 55 Gallon Ram

Module No. 570141

6

7

8

15

17

4

5

2

3

Ref.

No.


237261 PUMP, Bulldog, 31:1

235497 VALVE, check



214651 HOSE, coupled, 61209, 17 ft


158212 BUSHING

158555 NIPPLE, reducing

241253 RAM, pneumatic, EPDM, 55 gallon 1

1

1

1

1

2

1

1

1

Ref.

No.


30

31

32

33

20

26

28

29

37

39

40

41

C20487 FITTING, nipple, hex



276025 CLAMP

102637 SCREW, cap



100133 WASHER, lock




114363 VALVE, ball

Qty.

4

4

4

1

1

4

1

1

1

1

1

1

37

6

8

20

26

7

4

28

17

5

4

29

30

15

3

31

9348C

309790P 65

Parts

20:1 Senator on 55 Gallon Drum

Module No. 570309

10

11

12

13

14

22

23

7

8

9

3

6

1

2

Ref.

No.


570308 PUMP, 20:1 Senator Dura-Flo 750

207408 ELEVATOR, stationary

237579 KIT, repair

514944 VALVE, needle sst 1/2 MF 6000

159842 ADAPTER

100380 BUSHING, pipe

501764 FITTING, elbow 90°

1 in. npt(f) x 1 in. n

237309 COVER, drum

208536 COUPLER, line, air

158491 FITTING, needle

237578 SUPPORT, cover assy, sst



160032 NIPPLE

Qty.

1

1

1

1

1

1

1

2

2

1

1

1

1

1

35

36

38

39

40

41

42

43

44

45

Ref.

No.


29

31

32

33

34

24

25

26

28

102644 VALVE, ball


214656 HOSE, coupled 61209, 10 ft

102471 SCREW, cap hex head

102021 NUT, lock

205349 HOSE, coupled 61120, 15 ft

162449 FITTING, nipple, reducing


180916 FITTING, tee 3/4(m) run x 1/4(f) branch

214037 VALVE, ball


187614 NUT, jam

159446 GASKET, vellumoid

15C321 PLATE, cover


15C322 RETAINER, siphon tube

190999 NUT, retainer

238161 TUBE, siphon, hd agitator


Qty.

2

1

3

1

1

1

3

2

1

1

1

1

1

3

1

1

1

1

1

33

34

24

23

22

14

25

24

23

22

26

41

45

1

2,3

28

43

42

40

39

10

9

12 6 7

32

31

29

44

Detail A

38

8

35

31

11

10

36

44

13

See Detail A

66 309790P

Parts

9:1 DynaMite on 1 Gallon Can

Ram

Module No. 570249

5

6

7

3

4

1

2

3

Ref.

No.


235871 PUMP, extruder, sst, 190

217298 BRACKET, mounting

514518 HOSE, coupled 3/16 in. x 3 ft

109125 HOSE, coupled 72 in.

224908 INDUCTOR, assy, 1 gal.



Qty.

1

2

2

1

1

1

1

Ref.

No.


8

9

10

11

12

13

14

C24332 BOLT, “U”

100615 BUSHING, hex steel

101885 SCREW, cap sch

102040 NUT, lock, hex

100086 WASHER, plain



Qty.

1

1

1

2

2

2

1

5

7

7

3

9

1

4

13

2

10,11,12

8

6

14

8

309790P 67

Parts

10 Gallon Press Tank with 15:1

Booster

Module No. 570037

Ref.

No.


8

9

6

7

2

3

5

10

11

12

13

14

101946 PIN, cotter, sst

102325 ELBOW, 90°




217296 FRAME, pump

167682 ROD, tie

207352 MOTOR, air, pres

207370 ROD, connecting

215930 PUMP, displ, recip

221170 HOSE, coupled, 061260, 3 ft

236150 TANK, high pressure 10 gallon

Qty.

1

3

1

2

1

1

1

1

1

1

1

1

28

29

30

31

32

33

19

21

22

23

15

16

17

18

24

25

26

27

Ref.

No.


236662 AGITATOR, heavy duty, 10 gallon

236677 KIT, repair

501603 VALVE, check 1/2 in. npt mbe sst tf 1

512484 VALVE, ball, sst 1

1

1



100133 WASHER, lock


4

4

1

4

100016 WASHER, lock


150707 PLATE, designation



1

1

2

2



214656 HOSE, coupled, 61209, 10 ft



107142 VALVE, ball, vented

1

1

1

1

3

1

30

33

32

10

2,5,11,26

9

8, 19

15

31

6

21,22,23,24,25

29 28 27

12

7

32

32

18

17

14

3 13

16

68 309790P

Parts

10:1 President 5 Gallon Pail

Cover

Module No. 570264

4

5

1

3

Ref.

No.


903295 PUMP, 10:1 President, sst

100035 SCREW, machine, panhead

206755 CHAIN

165096 PLUG

Qty.

1

1

1

1

6

7

8

Ref.

No.



101962 SCREW, set sch

100220 SCREW, thumb

Qty.

1

2

3

6

5

4

3

Detail A

7

27

25

25

23

See

Detail A

19

13

8

20

1

30

28 29

21

11

12

14

15,16

10

9

24

22

21

309790P 69

Parts

Mix Kit Selection

Cartridge Fill Medium Viscosity

Wide Ratio

Module No. 570248

8

9

10

11

6

7

4

5

12

13

14

15

16

34

35

36

37

27

31

32

33

17

18

19

20

24

25

26

43

44

45

46

38

40

41

42

Ref.

No.


626748 BRACKET, mount disp valv C24342 1

552204 ACTUATOR, air, 8900 metered shot 1

C30021 BOLT, u


1

1


159801 UNION,swivel, 90°

504327 HOSE, nylon 3/4 in. id

504621 COUPLING, hose

4

4

1

1



175013 NIPPLE, pipe

512442 HOSE, bulk 1/2 in. nylon 3500 psi

503917 COUPLING, hose 1/2 ft npt(m) x

1/2, 3903

105281 UNION, swivel, 90° 1

512616 HOSE, PTFE 1/4 x 18 in. 1/4 npsm 1

500517 FITTING, tee 3/4 in. npt 1

1

8

2

2

8

158683 FITTING, elbow 3/4 in. npt



156684 UNION, adapter,

1

2

4

5

100840 ELBOW, street 2

512910 MUFFLER, polyethylene 1/4 in. npt 2

156971 NIPPLE, short 4

626758 MANIFOLD, block 8900 meter, shot 1

626757 BLOCK, check 8900 metered shot

C26088 VALVE, cone extension

C26086 STOP, cone, assembly

103374 SCREW, machine, rdh

1

4

1

1


C24017 ROD, trip, valve

C20068 PIN, spring

C24018 COLLAR, stop

C24020 COLLAR, clamp

598729 FITTING, elbow, male, 90°

513066 TUBE, 3/8 ft OD nylon

C12509 TUBE, nylon

3

20

1

4

2

2

1

1

51

52

53

54

47

48

49

50

80

81

82

83

75

76

77

79

84

85

86

70

71

73

74

66

67

68

69

60

63

64

65

56

57

58

59

Ref.

No.



552211 VALVE, pulse pneumatic

593538 VALVE, shuttle 1/8 npt(f)

503028 VALVE, air, push-pull

212099 KIT, accessory

100730 BUSHING

104984 TEE, pipe

C19391 FITTING, elbow 1/4 npt(m) x 1/4 od tube

512420 FITTING, cross steel 3/8 npt

100195 NIPPLE, pipe

103656 FITTING, pipe, hex

599433 FITTING, elbow, male

501014 ACTUATOR, air 1/8 npt(f)

114372 MIXER, static, 1/2 npt

158581 COUPLING, hex

948081 MIXER, tri-core 1/2(m) x 1/2(f)


690270 ADAPTER, luer lock 1/4 in. npt

112012 NOZZLE, needle


205324 HOSE, coupled, 61120, 1 ft

164672 ADAPTER


552208 VALVE, ball 3-way


552205 MIXER, pipe, sst 1/4-4.2 in. 12 el

626760 MANIFOLD, ratio check 8900 shot

102646 VAVLE, ball

156877 NIPPLE, long







2

2

1

2

1

1

2

2

2

2

2

1

1

1

2

2

2

1

2

2

1

2

2

2

1

1

1

Qty.

2

4

1

2

1

1

6

2

70 309790P

Parts

309790P

9

8

7

32

31

18

13

12 17 12

15,16

10,11

4,37

26

27

71

76 75 74 65

70

64

5

24

64

24

20

63

80

73

7

33

25

79

34,35,36,38

67

68,81,82,83

15,16

34

77

67

69,84,85,86

14

24

19

13,24

51

54

53

32

54

Detail C

46

46

59

43

44 45

41

47

52

56

57

42

46

60

52

46

47

58

50

47

46

60

58

47,48

46

49

44

54

45

40

See Detail C

44

71

Parts

Cartridge Fill High Viscosity

Wide Ratio

Module No. 570318

21

22

23

24

17

18

19

20

25

26

27

28

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

Ref.

No.


552204 ACTUATOR, air, 8900 metered shot 1




4

1

156877 NIPPLE, long


626757 BLOCK, check 8900 metered shot 1

626758 MANIFOLD, block 8900 meter shot 1

1

1


513375 MIXER, pipe sst 3/4-16.4 in. 2 el


160032 NIPPLE

552208 VALVE, ball 3-way




2

4

1

2

3

1

1

2

157350 ADAPTER, 3/8 npt x 1/4 npt

205324 HOSE, coupled, 61120, 1 ft


100040 PLUG, pipe



102646 VAVLE, ball

158491 FITTING, nipple, 1/2 npt


C26086 STOP, cone assembly

151249 NIPPLE, pipe

112698 ELBOW, male, swivel

1

1

1

1

1

1

2

1

1

1

1

1

33

34

35

36

37

29

30

31

32

38

40

42

47

48

50

51

61

63

64

65

54

55

58

60

66

68

69

Ref.

No.


C12509 TUBE, nylon


157191 FITTING, adapter

596832 FITTING, tee, tube




552211 VALVE, pulse, pneumatic


104631 VALVE. foot


H55033 HOSE, bulk 1/2 in. nylon 5600 psi

100133 WASHER, lock



512231 CONNECTOR, 1/4 od x 1/8 in. npt(f)


233415 KIT, accessory, ratio check



166466 TEE, pipe, female

104984 TEE, pipe



100176 BUSHING, hex

512616 HOSE, coupled 61120, 1.5 ft

100615 BUSHING, hex

2

2

2

2

1

1

6

2

2

1

2

1

2

5

1

1

1

1

Qty.

1

2

2

1

5

30

1

4

1

72 309790P

4

61

58

60

69

65

42 24 23 22

64

63

54

Detail C

37

17

18

11

31

10

11

12

42

61

See Detail C

See Detail A

Parts

42

See Detail C

68

16 15 14 9

Detail A

13 14 18 19

1

42

21

26

20

8

16

15

31

6

4

5

7

25

66

37

37

51

32

29

36

34

29

33

35

36

30

51

27

38

29

37

29

33

29

50

28

1

54

50

1

55

This view rotated 90° for clarity

6

309790P

40

73

Parts

Brush Grade High Viscosity

Wide Ratio

Module No. 570358

12

13

14

15

16

8

9

10

11

6

7

4

5

1

2

3

51

52

53

54

47

48

49

50

43

44

45

46

38

40

41

42

34

35

36

37

27

31

32

33

17

18

19

20

24

25

26

Ref.

No.

56

57


159841 ADAPTER

114112 FITTING, connector, female

100030 BUSHING


552204 ACTUATOR, air 8900 metered shot 1

C30021 BOLT, u


2

1

3

1

1



504327 HOSE, nylon 3/4 in. id

504621 COUPLING, hose


160327 UNION,

175013 NIPPLE, pipe

512442 HOSE, bulk 1/2 in. nylon 3500 psi

503917 COUPLINE, hose, 1/2 npt(m) x 1/2,

3903

105281 UNION, swivel 45°

512616 HOSE, PTFE 1/4 x 18 ft 1/4 npsm

500517 FITTING, tee 3/4 in. npt

158683 FITTING, elbow, 90°





512912 MUFFLER, polyethylene 1/2 npt

156971 NIPPLE, short 5

626758 MANIFOLD, block 8900 meter shot 1

4

2

1

2

5

5

1

1

1

1

8

2

2

8

4

4

1

1

626757 BLOCK, check 8900 metered shot


C26086 STOP, cone, assembly



C24017 ROD, trip, valve

C20068 PIN, spring

C24018 COLLAR, stop

C24020 COLLAR, clamp


513066 TUBE, 3/8 in. OD nylon

C12509 TUBE, nylon


552211 VALVE, pulse pneumatic




100730 BUSHING

104984 TEE, pipe


512420 FITTING, cross steel 3/8 npt(f)

100195 NIPPLE, pipe

11

2

2

1

6

20

1

6

2

5

1

2

2

2

1

1

1

4

1

1

1

1

Ref.

No.


72

73

74

75

68

69

70

71

54

65

66

67

58

59

60

63


599433 FITTING, elbow, male


114372 MIXER, static, 1/2 npt

158581 COUPLING, hex

948081 MIXER, tri-core 1/2(m) x 1/2(f)


690270 ADAPTER, luer lock 1/4 in. npt



205324 HOSE, coupled, 61120, 1 ft

164672 ADAPTER



552208 VALVE, ball, 3-way


82

83

84

85

76

77

79

80



102646 VALVE, ball

156877 NIPPLE, long

100175 COUPLING, pipe

511351 MIXER, static

108233 VALVE, needle


86

90

91

92

93

94

965766 VALVE, 1k-ul, machine mount

101353 NIPPLE, pipe



95

96

97

98

501459 VALVE, toggle, air

110460 FITTING, el male swivel,

10-32x5/32

598140 FITTING, elbow 5/32t x 1/8 in. npt(m)

510220 VALVE, air 4-way spring 1/4 npt


164815 FITTING, adapter, tee

99 503279 FITTING, union straight 1/8 in. mxf sw

100 112013 NOZZLE, needle






1

2

1

1

2

2

2

1

2

2

Qty.

1

1

1

1

1

1

1

1

2

2

1

1

2

1

1

3

1

1

1

2

2

2

1

2

2

1

3

2

4

1

1

74 309790P

Parts

27 82

9

8 32

7 31

18

12 17

13

12 15,16

10,11

4,37

26

83

70

71

32

84

82

85

47

86

27 63

75

64

20

65

24

5

24

90 91 92

7, 73

33

25

79

34,35,36,38

67

68

15,16

34

77

69

67

14

24

19

13,24

51

1

54

44

54

54

53

32

43

44

46

44

46

45

54

59

47

52

56

57

41 42

46

60

52

47

58

46

50

47

99 95

49

94

60

2

3

44

93

46

60

58

49

46

58

47,48

98

47

46

46

96

45

45

40

44

47

309790P 75

Parts

2K UltraLite 20 ft Automatic

(See Graco Manual 309000)

Wide Ratio Module No. 570144

Close Ratio Module No. 570362

2

3

4

5

8

9

10

11

12

Ref.

No.

1


570145 VALVE, 2k2 aluminum machine mount wide ratio (507144)

965534 VALVE, 2k-ultra lite, machine mount, sst (570362)

512291 NUT, mixer

512016 MIXER, 3/8 x 24 el dispos

10056-324

503536 FITTING, nipple, reducing, mod.





207946 SWIVEL, straight

552026 HOSE, PTFE/sst-10 hp 20 ft

503931 FITTING, adapter

1

1

2

100

1

1

1

1

2

1

1

17

18

19

20

21

22

23

Ref.

No.

13

14

15

16


617467 BUSHING, hex reducing 3/4 x 12

(570144)

100896 FITTING, bushing, pipe (570362)


189018 SWIVEL, 5800 pis (570144)

598140 FITTING, elbow 5/32T x 1/8 in. npt(m)

1

514607 TUBE, nylon 2.5mm id red

552071 SLEEVE, protective


104984 TEE, pipe

60

25

2

1

947937 VALVE, injector #40 1/4 npt

100721 PLUG, pipe

162449 FITTING, nipple, reducing (570362) 1

1

1

1

4

1

2

8

11

12 13

14

4

18

2 9 5

10

12

3

1

19

22

20

21 19

15

17

570144 16

2 9 5

10

12

18

3

1

19

22 21 16 17

20 19

570362

18

8

11 12 13

14

16

23 13 14

76 309790P

Parts

2K UltraLite 20 ft Hand Gun

Wide Ratio Module No. 570363

Close Ratio Module No. 570091

7

8

5

6

2

3

4

Ref.

No.

1


570182 VALVE, 2k ultra lite, aluminum, hand gun, wide ratio (570363)

965535 VALVE, 2k2, hand held, aluminum

(570091)

512291 NUT, mixer

512017 NOZZLE, mixer

162453 NIPPLE, (1/4 npsm x 1/4 npt)


501867 VALVE, check

205324 HOSE, coupled, 61120, 1 ft

H52525 HOSE, fluid nylon; 1/4 in. (6.4 mm)


Qty.

1

1

2

50

2

1

1

2

2

Ref.

No.

9

10

11

12

13

14

15

16

17

18

19



207946 SWIVEL, straight










189018 SWIVEL, 5800 psi (570091)

Qty.

1

1

2

2

1

3

1

2

30

25

2

2 4 5 6

7

9 10

12 11

12

11 12 13 14

16

3

1 4 5 6 16 17 8

15

18

570363

2 4 5

6

7 19

9 10

12 11

3

1 4 5 6

19

16

17

8

12

18

5700091

309790P

11 12 13

14

16

15

77

Parts

2K UltraLite 15 ft Hand Gun

Wide Ratio Moisture Lock

Module No. 246588

7

8

5

6

2

3

4

9

10

11

Ref.

No.


1 570182 VALVE, 2k ultra lite, aluminum, hand gun, wide ratio (570363)

189018 SWIVEL, 5800 psi

512288 MIXER, disposable .5 x 24 in.

162453 NIPPLE, (1/4 nps(m) x 1/4 npt)


501684 VALVE, check

235905 HOSE, coupled, 2.5 ft

514428 HOSE, 1/4 in. PTFE x 10 ft

162024 COUPLING

161490 COUPLING, reducing

512247 HOSE, 5/8 PTFE 7.5 ft 3/4 npt(m)

Qty.

1

1

20

4

1

2

2

1

1

1

2

17

18

19

20

21

22

Ref.

No.


12

13

14

15

16


214925 SWIVEL, hose






512297 SLEEVE, mixer jacket


947937 VALVE, injector #40 1/4 in. not

100730 BUSHING

Qty.

1

2

1

2

32

15

1

1

1

1

1

14

16

11

22

17

14

12

18

2 4 1

9

6

13

20

21 5

4

19

4

5

TI3262A

3

78 309790P

Parts

High Volume Static Mix Manifold

Module No. 570391

3

4

1

2

5

6

Ref.

No.



512151 VALVE, ball

175013 NIPPLE, pipe

235497 VALVE, check



Qty.

4

2

2

2

2

1

8

9

10

11

Ref.

No.

7


501392 FITTING, cross 3/4 in. npt cs 2000 psi



214037 VALVE, ball

204938 HOSE, coupled, 61120, 25 ft

Qty.

1

1

1

1

1

12

1

2

3

4 3

5

6

7

8

1

2

3

4

3

5

9

10

TI3261A

309790P 79

Parts

High Volume Static Mix Kit with

Pump Pilots

Module No. 570263

Ref.

No.


8

9

10

11

12

13

14

6

7

4

5

1

2

3

504704 FITTING, nipple, hex

512152 VALVE, ball 2000 psi 1 in. npt(f)

514058 MIXER, pipe 1 in. x 12

158383 FITTING, union, adapter, straight

500946 HOSE, 1 in. mbe

502766 FITTING, cross 1 in. npt(f) sst

160327 UNION, adapter 90°

175013 NIPPLE, pipe

235497 VALVE, check




214037 VALVE, ball

204938 HOSE, coupled, 61120, 25 ft

Qty.

1

1

1

2

1

4

2

1

2

2

1

1

1

3

30

32

33

34

Ref.

No.


21

22

23

26

15

16

18

20

27

28

158586 FITTING, bushing


C12509 TUBE, nylon

104632 VALVE, piloted

512912 MUFFLER, polyethylene 1/2 npt


C20344 FITTING, tee 1/8 brass

104631 VALVE, foot

522071 SLEEVE, protective; 2.1 ft

C19391 FITTING, elbow 1/4 npt x 1/4 od tube

100474 COUPLING; pipe

512151 VALVE, ball



Qty.

1

1

2

2

80

2

3

3

1

2

2

1

1

2

80

14

34

33 10 32 8 9 8 7 15

6 3 30 3 4 5 4 3 2 1

33 10 32 8 9 8

11

15

12

7

13

16 18 28

26 28

20

18

16 18

21

22

18

17

23 17 18 16

21

22 20

309790P

Stanchion

Module No. 570071

3

4

1

2

Ref.

No.


167636 BASE, ram

167639 BRACKET, cylinder

176629 CYLINDER, ram


Qty.

1

1

1

4

4

3

1

2

Parts

309790P 81

Parts

Boom Assembly

Module No. 246589

7

8

5

6

9

3

4

1

2

Ref.

No.


947039 FRAME, boom, swivel, 55 gal

158383 FTIING, union, adapter, straight

157262 WASHER, plain

158555 NIPPLE, reducing




552231 HOSE, PTFE 1/4 x 12 ft 3000 psi

500946 HOSE, 1 in. mbe

Qty.

2

1

2

1

1

4

2

1

1

Ref.

No.


10

11

13

14

15

16

17

18

19

20

622070 BRACKET, boom


103473 STRAP, tie, wire

570071 BASE, stancion mounting

606937 FITTING, bulkhead

100056 NUT, jam hex

202966 FITTING, union, adapter


160032 NIPPLE

166999 FITTING, elbow, street

Qty.

1

1

1

1

1

1

1

2

3

See Detail A

5

18

20

Detail C

19 11

4 2 9

17

4

See Detail B

11

Detail A

10

6 5 8

15

3

16

7

Detail B

13

1

14

8

9

See Detail C

82 309790P

Parts

309790P 83

Technical Data

Technical Data

Maximum system working pressure . . . . . . . . . . . . . . . . . 2000 psi (13.8 MPa, 138 bar)

Maximum air input pressure . . . . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)

Main air inlet size (8900 Proportioner) . . . . . . . . . . . . . . . 3/4 npsm(f)

8900 Proportioner outlet size

Component A Pump. . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)

Component B Pump. . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)

8900 Proportioner inlet size

Component A Pump. . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)

Component B Pump. . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)

8900 Proportioner wetted parts Carbon steel, stainless steel, zinc, black oxide, PTFE, fluoroelastomer, electroless nickel, aluminum, nylon

•

Refer to pump Output Charts on pages 15-17 for ratio adjustment and displacement pump part number

information.

• For additional wetted parts information and technical data, refer to your separate component manuals.

Accessories

570264 President 10:1 mounted on a 5 gallon (19 liter) pail. Used for solvent flush of mix kit assembly.

Repair Kits for A and B Metering Cylinders

Size Meter Repair Kit

Cup

(Order 2)

#1000 C24166 or 289402 C05032

#500

#250

C24166 or 289402

C24166 or 289402

C23350

C23318

#111

#100

C24166 or 289402 15C181

C24166 or 289402 C22282

Ratio

Cylinder

C23136

C23200

C23171

15C180

C23137

Ratio Kit*

C23041

C23087

C23067

C23042

Cylinder Repair Kits Cross Reference

289402 Repair Kit

EDPM 8900 Cylinder

15R212

15R213

C21002

C36244

C36246

C24166

Repair Kit

188554

C20278

C21002

C36244

C36246

Qty.

2

2

10

2

2

Description

PACKING, o-ring

PACKING, o-ring

PACKING, vee

GLAND, male

GLAND, female

84 309790P

Repair Kits for All Proportioners

For Part Number

Actuator C24046

Repair Kit Replacement Parts

C24047

4-Way Valve, 3/16 in. C24039 C07067 or 289401 C07069 Trunion 3/16 in. inside port

4-Way Valve, 5/8 in. C24029 C07067 or 289401 C07068 Trunion 5/8 in. inside port.

4-Way Valve Repair Kits Cross Reference

289401 Repair Kit

EDPM 8900 Cylinder

15R207

15R208

15R209

15R210

15R211

15R214*

C07067

Repair Kit

C24032

C24035

C24036

C24040

103611

C24031

C24037

C24031

C24037

C24038 C24038

* This part is equivalent to 105802

Qty.

Description

4

4

4

1

2

2

4

2

4

PACKING, o-ring

PACKING, o-ring

PACKING, o-ring

PACKING, o-ring

PACKING, o-ring

PACKING, o-ring

SEAL

BUSHING

RING, backup

Technical Data

309790P 85

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by

Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED

TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

This manual contains English. MM 309790

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

Copyright 2003, Graco Inc. is registered to ISO 9001 www.graco.com

Revised 07/2009

Graco 309790P - 8900 Proportioner Instructions

Instructions - Parts

8900 Proportioner

309790P

Configured product offering for dispensing fixed or variable ratio of two fluids.

Contents

Manual Conventions

Warning

Caution

Note

Warning

Theory of Operation

Use

Major Components

Ratio Proportioning

System Components and

Operation Overview

Feed Systems - Feed Pumps

Feed Systems - Alternative Feed Supplies

Pump Fluids to the Mixer

Mix the Fluids

Ratio Checks

Dispense Valve

Models

Installation

Typical Installation

Location

Ground

Flush

Setup

Set the Ratio (variable ratio models only)

Adjust ratio

Set Scale

Output Charts/Ratio Settings

8900 Proportioner, 1:1 - 4:1 Variable Ratio

8900 Proportioner, 2:1 - 8:1 Variable Ratio

8900 Proportioner, 5:1 - 20:1 Variable Ratio

Before You Load Material

Load Component A

Prime Pump A

Load Component B

Pneumatic Pail Ram and Piston Pump

Pressure Tank with 15:1 Booster

Prime with Component B

Fill the 8900 Proportioner with

Material

2K UltraLite Disposable Mixer Gun Models

All Models

Operation

Pressure Relief Procedure

Dispense Mixed Material

8900 Proportioner with Static Mix Chamber

Kits

Adjust the Flow Rate

Solvent-flush Mixed Material (for units using mix manifold gun kits)

8900 Proportioner with Disposable Mixer

Gun

Changing Component A Drum

Changing Component B Pail

Pressure Relief Procedure

Filling Component B Pressure

Tank

Adjust Ratio on Variable Ratio Machine

Verify the Ratio

Daily Procedures

Daily Start-up Procedure

General Ratio Check Procedure

Daily Shut-down/Purge Procedures

X

Troubleshooting

8900 Proportioner Operating

Pressures

What the fluid gauges tell you

Air Supply Troubleshooting Chart

Pump Troubleshooting

Overview

Pump Cavitation

Pump Failure to Seal

Component B Pressure Relief Valve

Troubleshooting Guide: Feed pumps