Graco 308986A HYDRA-CAT FIXED RATIO Proportioning Pumps Owner's Manual

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Graco 308986A HYDRA-CAT FIXED RATIO Proportioning Pumps Owner's Manual | Manualzz
INSTRUCTIONS
308986
manual This
contains important
warnings and information.
READANDKEEPITFORREFERENCE.
i ’
GRACO
Rev. A
First choice when
qua/ity counts.
INSTRUCTIONS
HYDRA-CAT” FIXED RATIO
Proportioning .Pumps
Available as Bare Pumps,*
Wall-Mounted* or Free-Standing* Models
*Includes Automatic Pressure Relief Valves, Check
Valves, Pressure Gauges and
Regulators
CODE NUMBER
Enter Code Number Here
WARNING
Plural Component Materials Hazard
Graco Inc. does not manufacture or supply any of the reactive chemical materials thatbemay
used in this equipment and
is notresponsible lor their effects. Because of the vast number of chemicals that could be used
theirand
varying chemical
reaction, before usingthis equipment the buyer and the user should determine
all facts relating to the materials used,including any of the potential hazards involved. Particular inquiry and investigation should be made into the potential dangers relating to toxic fumes, fires, explosions, reaction times, and exposure of human beings
to the individual components
or their resultant mixtures. Graco assumesno responsibility forloss, damage, expense or claims for bodily injury or property damage, direct or consequential, arising from the use of such chemical components.
I
GAACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441
@COPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I S . EN I S 0 9001
Table of Contents
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.
.
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.....
.. . ...
. .. .
. . . . . .. .
.. .. . . .
. . . . . . . . . . . . . . . . ..
. .. . . . . . . . . . . . . . .
Warnings . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 3
System Information . ,
..
. . .. . . . ..
6
Typical Installation . . . . . . . . . . . . . . . . . . . . 7
Dimensions . . . . . . . . . . . . . .
. . . . . . 17
Flushing.. . . . . . . . . . .. .
... .
. . 18
Operation
. . . . . . . . . . . . . . . . . . . 21
. .
. . . .. . . .
..
. ... . .. . . . ..
. .. . . ..
Shutdown and Care of the System . . . . . . . . . . . . . 26
Troubleshooting . . . . . . . . . . . . . . . , . . . . . , , 27
Service Displacement pump.. . . . . . . . . . , , . . . . 29
Graco Warranty . .
. . . . . . . . . . , . . . . . . 32
Graco Phone Number.. . . . . . . . . . . . . . . , . . 32
-
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!
Warnings
Warning Symbol
Caution Symbol
Thissymbolalertsyou to thepossibility of seriousThissymbolalertsyou
to thepossibility of damageto
or destruction of equipment if you do not follow the
injury or death if you do not follow the instructions.
instructions.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
ir
serious injury.
This equipment is for professionaluse only.
Read all instruction manuals, warnings, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage,call your Graco
distributor.
Do not alter or modiy this equipment. Use only genuine Graco parts and accessories.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
See Configurator Product Order Form309002 for important pressure rating information. The maximum working pressure of each model isalso shown on the pump identification plate. Be sure that
all dispensing equipment and accessories are rated to withstand the maximum working pressure
of
rated system component.
your pump. Do not exceed the maximum working pressure of the lowest
t..
Never operate the pump without the automatic pressure relief valves and drainage kits installed.
These valves relievefluid pressure through a drain port at the bottom of the valve if the displacement pump pressure exceeds the working pressure.
B
Never exceed the recommended working pressure or the maximum air inlet pressure stated
on
your pump orin the Configurator Product Order Form309002 .
Do not lift pressurized equipment.
B
Use only Graco approvedhoses:Do not remove hose spring guards, which help protect the hose
from rupture caused by kinks or bends near
the couplings.
B
Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces.
Do not
expose Graco hosesto temperatures above 180°F (82°C) or below -40°F (-40°C).
B
Do not use the hoses to pull the equipment.
B
Use fluids and solvents that are compatible with the equipment wetted parts. See the Technical
Data section of all the equipment manuals. Read the fluid and solvent manufacturer's warnings.
B
Comply with all applicable local, state and national fire, electrical and other safety regulations.
c
308986
3
:NJECTlON HAZARD
Spray from the spray gun, hose leaks, or ruptured components can injectfluid into your body and
:ause extremely serious injury, including the need for amputation. Splashing
fluid in the eyes or on the
;kin can also cause serious injury.
b
Fluid injected into the skin might look like just a cut. butisita serious injury.Get immediate medical attention.
b
Do not point the gunhalve at anyone or at any part
of the body.
b
Do not put your hand or fingers over the spray
tiplnonle.
Do not stopor deflect fluid leaks with your hand, body, glove, or rag.
1
Do not "blow back" fluid: thisis not an air spray system.
I
Check the gun diffuser operationweekly. Refer to the gun manual.
1
Always have the trigger guard on the gun when dispensing.
1
Check the gun diffuser operation weekly. Referto the gun manual.
1
Be sure the gun/yalve trigger safety operates before dispensing.
1
Lock the gunhalve trigger safety when you stop dispensing.
1
Follow the Pressure Relief Procedure on page 21 ifthe nozzle clogs, and before cleaning, checking or servicing the equipment.
1
Tighten all fluid connections before operating the equipment.
1
1
Check the hoses, tubes, and couplings daily. Replaceworn, damaged, or loose parts immediately.
Do not repair high pressure couplings: you must 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.
'IRE, EXPLOSION AND ELECTRIC SHOCK HAZARD
mproper grounding, poor air ventilation, openflames, or sparks can cause a hazardous condition and
esult in fire, explosion, or electrostatic shock and other seriousinjury.
Ground the equipment, the object being dispensed,
and all other electrically conductive objectsin
the dispense area. Proper grounding dissipates static electricity generated
in the equipment. Refer
to System Groundingon page 10.
Provide freshair ventilation to avoid the buildup of flammable fumes from solvent or material.
.
Do not use the heater with flammable liquids, such as those havingflash points below 200" F
(93" C).
Extinguish all open flames or pilot lights in the dispense area.
Do not turn on or off any light switch in the dispense area.
Do not use this equipment with flammable liquids.
Keep the dispense areafree of debris, including solvent, rags, and gasoline.
Do not smoke in the dispense area.
4
B
Do not operate a gasoline engine within the spray
area.
B
If there is any static sparking or you feel an electric shock while using the equipment,
stop dispensing immediately. Do not use the equipment until you have identified and and corrected the
Droblem.
308986
MOVING PARTS HAZARD
i
Moving parts can pinch fingers.
rn Keep clear of all moving parts when starting or operatingthe equipment.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death
if splashed in the eyes or on the
skin, inhaled, or swallowed.
rn Know the specific hazards of the fluid youare using.
rn Store hazardous fluidin an approved container. Dispose of hazardous fluid according to all local,
state and nationalguidelines.
rn Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
Avoid exposure to heated materialfumes.
Provide adequate ventilation,
Graco does not manufacture or supply any of the reactive chemical components that may be
used in this equipment andis not responsible for their effects. Graco assumes no responsibility
for loss, damage, expense or claims for personal injury or property damage, direct or consequential, arising from the use of such chemical components.
c
308986
5
System Information
This manual describes pumps designed to be part of a
The basic proportioner includes an air motor, lower
Hydra-Cat
dispensing
system
that
will
proportion,
mix,
displacement
pumps,
air
controls,
fluid
inlet
hardware,
anddispensetwo-componentfluids.Thefixedratiofluidoutlethoses,manifoldblocksandreliefvalve.
proportionersaccuratelypumpandproportiontwo-Additionalproportioneraccessoriesareselectableto
component materials by powering two orthreepositiveCompletetheproportionerpump(seeConfigurator
displacementpumplowersfrom a commonairmotor.ProductOrderForm
309002 ).
This assures that the stroke rate and stroke length
of
all pump lowers are identical, providing constant proportioning. The mix ratiois fixed by selecting compatible sets of two or three lowers (see Confgurator
Product Order Form309002 ).
;,
i
6
308986
Typical Installation
About Typical Installations
The typical installations shown below and on page
8
are only guidelines to setting up
a complete proportioning system. For clarity, various components are
shown in the correct orderbut may not be shownin the
exact positionof the installed system. For assistancein
designing your system, contact your nearest Graco
representative.
NOTE When pressure feedingthe proportioning
pump, mount fluid pressure gauges (J) at the proportioning pump inlets to monitor proper adjustment
of the
feed pump pressures. Neverexceed 400 psi on the
inbound fluid pressure and never exceed 25% of
the Hydra-Cat pump outbound fluid pressure on
the feed supply.
Two Displacement Pumps,
with Feed Pumps
KEY
A
B
C
D
E
F
G
Bleed-type
master
air valve
Airfilter
Air iubiicator
Pump runawayvalve
Pumpairreguiator
Feedpump
Groundwire
H Proportioning pump
fluid
drain
valve
P
fluid pressure
gauge
0 Fluid
shutoff
valve
RConnect
mixer
Static
K Check valve
L Automaticpressurerelief
S Dispensevalve
valve
reguiator
T Fluid
U Sotvent pump
M Fluidfilter(Optional)
V Fluidstrainer
N Mixermanifold
J
A
See note above
tobottle.
drain
308986
7
Typical Installation
About Typical
Installations
NOTE: When
pressure
feeding
proportionina
the
pump, mount fluid pressure gauges(J) at the proporThe typical installation shownbelow, and on page7,
tioning pump inlets to monitor proper adjustment of the
are Only a guidelines to setting
a completepropor-feedpumppressures,
Never exceed 25% of the
tioning system. For clarity, various components are
Hydra-Cat pump outbound fluid pressure on the
shown in the correct order but may not be shown in the
feed
exact positionof the installed system. For assistance in
designing your system, contactyour nearest Graco
representative.
"
j'
Heavy Viscosity Heated System
Three Displacement Pumps,
Ratio Feed Pumps
KEY
A
Bleed-type masterair valve J
8 Airfilter
CAirlubricator
0 Pumprunawayvalve
E Pump
regulator
air
pump
Feed F
G Groundwire
H Proportioningpump
Fluid pressure gauge
K Check valve
L Automaticpressure
valve
relief
M Fluid finer
(Optional)
N manifold
Mixer
P Fluid
drain
valve
Q
Fluidshutoff valve
R mixer
Static
S Dispensevalve
Tregulator
Fluid
U Solvent
pump
V Fluidstrainer
X Supply
manifold
A
A
See note above
Connect io drain bottle.
See Fig. 5. page 11
I'
A
Fig. 2
'H
"
"
-
L
I
~U
02812
i
Installation
Bare Pumps
('
Bare p,umps, with relief valves and inletkRs but without
stands, are available for those installations which
require a highly customized
system. For a safe and
efficient system,Graco recommends that the air and
fluid components supplied with the Wall Mount and
Stand models also be usedin customized systems. In
addition, the accessories shown in the Typical Installation drawings and discussedin the following pagesOf
this manual should be used.
Be sureall accessories are sized properly for the air
and fluid requirements of your system.
NOTES:
1. Models with three displacement pumps always use
the two outer displacement pumps to supply the
resin andthe middle displacement pumpto supply
the hardener.
2.
Label all pumps, hoses, fluid regulators, etc. to
indicate whether they are
for the resin sideor
hardener side of the system.
Mounting the Pump
Mount the pump to suit your installation. The bare
pump can be mounted on a wall bracket or
on a stand.
See the Mounting Hole Layout on page17.
For a wall mount, be sure the bracket and wall are
strong enoughto support the pump, accessories,
Readallinstructions in theInstallationsectionforplumbingandstresscausedbypumpoperation.
bracket
about
further
details.
Locate
the
5 ft (1.5floor.
m)the
above
308986
9
Installation
2. Air hoses: use only grounded hoses with a maximum of 500 feet (150 m) combined hose lengthto
Grounding
ensure grounding continuity.
FIRE AND EXPLOSION H-D
Improper grounding couldcause static
sparking, which could cause a fire or
explosion. To reduce the risk of property
damage or serious injury, follow the
wounding instructions below.
The following grounding instructionsare minimum
requirements fora system. Your system may include
other equipmentor objects whichmust be grounded.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment. Your
system must be connected to a true earthground.
1.
3. Fluid hoses: use only grounded fluid hoses.
4.
Hydraulic Power Supply or Air compressor: follow manufacturer's recommendations.
5. Spray gun or dispensing valve: grounding is
obtained through connectionto a properly
grounded fluid hose andpump.
Pump:
a. Loosen the grounding lug locknut (Fig. 3,
Item BB) and washer (AA).
b. Insert one end of a 14 ga. (1.5 mm2) minimum
ground wire (G) into the slot in lug (GC) and
tighten the locknut securely.
6. Fluid supply container: according to local code.
7. Object being sprayed: according to your local
code.
c. Connect the other endof the ground wire to a
true earth ground.
8. All solvent pails used when flushing, according
to local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place
the pail on a nonconductive surface, such as paper
or cardboard, which interrupts the grounding continuity.
9. To maintain grounding continuity when flush-
cc
10
308986
/
ti
ing or relieving pressure, always hold a metal
part of the dispensing unit firmlyto the side of a
grounded metal pail, then triggerthe dispensing
unit.
Installation
Air Control Accessories
Install the accessories in the order shown in Fig. 4.
Mount only the air regulator(E)and a master air
valve (A) at the pump. Mount all other accessories on
separate wall brackets to reduce stress on the pump
inlet. Note that one air filter (B)can serve multiple
pumps by using an air manifold downstream from the
air filter.
3. install a pump runaway valve (D)for each feed
pump to automatically shut off the air to the pump
if the pump accelerates beyond the pre-adjusted
setting. A pump which runstoo fast can beseriously damaged.
4.
Install an air line lubricator (C) for automatic air
motor lubrication.
5. Install an air filter (6)
to remove harmful dirt and
moisture from the compressed air supply.
Automatic Pressure Relief Valves
INJECTION HAZARD
Bleed-type master air valves
(A) are required in the
system in the positions shown in the Typical Installation drawings. Thesevalves are used during
system' pressure reliefto relieve air trappedin the
air line. Trapped air can cause the pump to cycle
unexpectedly and resultin serious injury from
moving parts, fluid injection, or fluid splashing.
COMPONENT RUPTURE HAZARD
To reduce therisk of component rupture,
which could cause serious injury and
property damage, the appropriate automatic pressure relief valve(A) is required for each
fluid on a plural component pump.
These valves automatically relievefluid pressure if
the pump output pressure exceeds the valve's
preset pressure. Over-pressurization may occur if
there is a fluid line clog upstream from the valve or
if any other condition exists that causes one of the
pumps to cavitate and direct allfluid pressure to
the other pump(s).
I
I
-
See Configurator Product Order Form309002 to
determine the preset pressurein your system.
,/
C
Fig. 4
02887
1. Install a bleed-type master air valve (A) in the
pump air inlet.
2.
Install an air regulator and gauge (E) to control
pump outlet pressure.
NOTE: Drainage Bottle Kit
includes items fastening hardware shown
02888A
Fig. 5
308986
11
Installation
Automatic Pressure Relief Valves
(continued)
Two drainage bottle kits(a) are included with the stand
mount modelsto catch the drainageif the automatic
pressure relief valves (A) open.
Additional System Components
(
Install and connect the feed pumps, solvent pump,
heaters, etc. Refer to the Typical Installations (Fig.2)
for parts information.
Use a dry air kit or a nitrogen regulatorkit to protect
the fluid in the supply containers from moisturethat
can crystallize the fluid and cause the ball checks
to
malfunction. See Accessories in Configurator Product
Order Form 309002.
INJECTION HAZARD
Fluid emitted fromthe automatic pressure drain
valves may be at pressures over
3000 psi (21
MPa, 207 bar). To reduce the risk of serious injury
from fluid injectionor fluid splashing, make sure the
drain bottles are securely fastened to the frame or
wall so that they can handle a sudden spurt of
oressurized fluid.
\
\
Connect Fluid Supply Hoses
NOTE: If you mount the pump on a wall, turn the
displacement pump inlet assemblies (CC)
to face
forward, rather than backwardsas shown in Fig. 6.
Two Displacement Pump Models
1. Connect the resin supply hose (€E) to the 3/4 npt
swivel inlet (378) for the resin displacement pump.
See Fig. 6.
2.
Connect the hardener supply hose (DD) to the
3/4 npt swivel inlet (37A) for the hardener displace-
ment pump. See Fig. 6.
Three DisplacementPump Models
1.
Connect the resin supplyhose (EE) to the 3/4 npt
swivel inlet (378) for the resin displacement
pumps. See Fig. 7.
2. Connect the hardener supply hose (DD) to the 314
npt swivel inlet (37) for the center (hardener)
displacement pump. See Fig. 7.
Fig. 7
02890
i
12
308986
-
installation Optional Fluid Heaters
INJECTION HAZARD
To reduce the risk of serious injury,
follow the Pressure Relief Procedure
AI1 Models
1. Mount a heater to each side of the mounting
bracket using the three screws (201a) and lockwashers (201b) supplied with each heater. See
Fig. 8.
2. Connect a Swivel union (202) to the outlet of each
heater. See Fig. 8.
3. Connect a swivel uni6n (203) to the inlet of each
heater. See Fig. 8.
308986
13
-
Installation Optional Fluid Heaters
Two Displacement
Pump
Models
1. Loosen
swivel
the
ofunions
the
(Fig.
9, Itemsl7A,
178) to remove the elbow (Figure 10, Items 16A,
168) on each sideof the mixer manifold (23).Turn
the unions (17A, 178) so the outlet facesup.
2. Connect a new hardener fluid hose (2048)
between the.union (178) and the swivel (2038)at
heater
theinlet.
See
Fig.
9.
FA \
2
4-
RES
3. Install
another
hardener
fluid hose (FB) between
the heater outlet elbow (2028) andthe hardener
side of the mixer
manifold
(23).
4. Repeat Steps 1 to 3 for the resin side of the
system (the "A" side).
See
Three
Displacement Pump Models on next page.
1
I
HEATER
I
4-
I
I
-1
I
t
203A'
16A
168
23
Fig. 10
14
~~
308986
OUT
I
I
I
I
I
i
"_J
Fig. 9
+/
HARD I
)
1
r
"
"
"
202A,
I
Installation - Optional Fluid Heaters
2048
FA \
ZOW,
i
i
203A
_.
."
Fig. 11
(..
Three Displacement Pump Models
16A
1. Loosen the swivel of the unions (1 7A, 178) to
remove the elbow (16A, 168) on each side of the
mixer manifold (23). Turn the unions (17A, 178) So
the outlet facesup. See Fig. 11 and 12.
2. Connect a new hardener fluid hose (2048)
between the union (178) and the swivel (2038) at
the heater inlet. See Fig. 11.
3. Install another hardener fluid hose (FB) between
the heater outlet elbow(2028) and the hardener
side of the mixer manifold (23).See Fig. 11.
4.
Repeat Steps 1 to 3 for the resin side of the
system (the -A" side).
308986
15
Installation
- Optional Solvent Pump
NOTE Theoptionalsolventpump is notoffered as a
4. Couplethehose(303) andcouplings(302).
kit;orderpartsasneeded.TheseinstructionsassumeConnectthehose(303)
to the adapter(301).
that the Pump is being mounted to the backof the
stand offered in thismanual. The Typical Installations
5. Install the other adapter (301),needle valve (304)
on pages 7 and 8 shows an alternate installation.
Adjust
your
installation
according
to
your
specific
and
adapter
(305)
to the
pump
inlet.
needs.
1. Mount the solvent pump bracket (310) on the back
of the stand.
i
6. Connect the adapter (307), elbow (308) and fluid
hose (309) to the pump outlet.
2. Mount the pump (306) to the bracket using the
hardware supplied with the pump.
7. Install a fluid shutoff valve (311) at the mixer
manifold swivel union (15). This valve is used to
prevent resin or hardener from backing up into the
3. Use the existing proportioning pump air
solvent system, and to isolate the solvent system
regulator (5) to supplyairtothesolventpump.forservice.Connectthesolventinlethose
(309).
Remove the plug from the back of theswivel
union (3) and install the adapter (301). Rotate the
8. Connectthesuctionhoseassembly(312)
to the
regulatorgaugeelbow(4) so thegauge is facing
the operator.
309
@
3
5
Monarch 1O:l Shown
i
Fig. 13
16
308986
02802
Dimensions
308986
17
Flushing
WhenFlush
tothe
System
HowOperate
to the
Flush the system before its first use to remove the
light oil which was leftin after factorytesting.
Mixer Manifold
Push handle (KK) downto open or up to close the
mixer manifold fluid valves (LL) . See Fig. 14.
Flush the manifold mixer (N),using the solvent
pump, as frequently during theday as necessaryto
avoid exceedingthe pot life limit of the material
being pumped.
Flush frequently enough during regularoperation to
prevent clogged passages dueto material being
overheated or dried out in any part of the system.
Clogged passages in the heater can be very difficult
to clean and can reduce heating efficiency, flow rate
and pressure.
Flush the entire system when the system is shut
down for a long periodof time. Keep in mind that
the
some moisturemay get intothe lines, which could
contaminate the hardener, so flush again before
restarting
system.
Fig. 14
KEY
A
Bleed-type
master valve
air
A1 Hardenerfeedpump
A2 Resin feed pump
A3 Proportioning
pump
A4 Solvent pump
AS FeedandProportioningpumpmaster
valve
air
A6 Solvent pump masterair valve
A5
Fig. 15
308986
18
E Pump
air
regulator
E l Hardener
pump
feed
E2pump
feed
Resin
J
E3 Proportioning pump
E4 pump
Solvent
Fluidpressuregauge
J1 Proportioning pump intake
J2 Proportioningpump o u t l e t
H Proportioningpump
N manifold
Mixer
Q Fluid shutoff
vatve
Q1 Proportioning pump intake
Q2
manifold
inlet
solvent
Mixer
/
A6
02914
Flushing
How to Flush the System
7. Open the hardener side drain valve (Pl). Open the
mixer manifold handle(KK). See Fig. 14.
HOT SURFACE HAZARD
If your system is equipped with heaters,
always shut off the main power
to the
heaters just priorto completing spraying.
Shut off heater 10 minutes priorto shutdown to
cool the fluid and the
heater. This reduces the risk
of serious injury from burns. Flush system immediately after shutdown.
For flushing oil froma new system.
..
8. Slowly increase the air regulator (El) setting until
the pump is running slowly.
9. When the hardener lines are flushed, close the
mixer manifold handle and close the drain
valve (PI). Close the air valve (AI). See Fig. 15.
IO. Repeat Steps6 to 9 for the resin feed pump. The
resin sides uses these parts: regulator(E2),air
drain valve (P2).
valve (N),
To flush the solvent valves.
..
NOTE: Forflushingthefirst time,werecommend11.Open
thehardenersolventflushvalve
(NI) onthe
(N). SeeFig.14.
usingmineralspirits to flush out the oil. Next, flushmixermanifold
is compatible withthe fluid
again using a solvent that
(E4) is
youwill bedispensing.However, be suretheminerala.Besurethesolventpumpairregulator
spirits compatible
is
with
the
material
you
will
be
at minimum
pressure. See Fig. 15.
pumping. If itis not compatible, checkwith your fluid
b. Open the solvent pump main master air
supplier to determine an appropriate solvent for
lightthe
flushing
out
(A6)
valve
oil.
then
and
open
air
pump
the
valve (A4): See Fig. 15.
to to be
NOTE: The proportioning pump does not need
c. Release the dispensing valve safety latch.
running to clean oil from the system. Feed pump
Hold the dispensing valve firmly against a
pressure is adequate to flush the system with solvent.
grounded pail and trigger it while slowly
(€4).
opening the solvent pump air regulator
1. Place each feed pump intake into a separate 5
Operate
the
pump
slowly
until
the
dispense
gallon grounded pail, containing about3 gallons
line is flushed. Release the dispensing valve
(12 liters) of solvent.
trigger and engage its safety latch. Close the
hardener solvent flush valve(NI).
To flush or prime
...
2. Be sure both of the fluid shutoff valves(QI) are
open. See Fig. 15.
d.
3. Place a container under the drain valves
(PI ,P2) of
the mixer manifold (N). See Fig. 14.
e. Close the solvent iine shutoff valve (Q2). See
Fig. 15.
4. Be surethe feed pump air regulators(El,E2) are
at minimum pressure. See Fig. 15.
5. Open the main master air valve(As).See Fig. 15.
6. Open the hardener pump master air valve(Al).
See Fig. 15.
Open the resin solvent flush valve (N2) and
repeat Step c., above. See Fig. 14.
A
I
CAUTION
I
Always close the solvent line fluid shutoff valve (Q2)
aftertheflushingprocedurehasbeencompleted.
This will prevenithe other fluidsfrom leaking into the
flushing line.
308986
19
Flushing
.
If this is a first time flush. .
12. Repeat the flushing procedure using a solvent
compatible withthe fluid you are going to dispense.
...
When you are done flushing
13. Remove the solvent supply from the feed pumps.
Operate the pumps slowly
to push all the solvent
out of the lines, then stop the pumps.
I f you are not going to use the system. . .
14. Close all air regulators, master air valves and fluid
shutoff valves. Follow thePressure Relief Procedure on page 21.
20
308986
INJECTION HAZARD
To reduce therisk of seriius injury from fluid injection or fluid splashing, alwaysclose the air
valve (A4) to the solvent pump before openingthe
fluid drain valves (P2)to relieve system pressure.
This will reduce the riskof excessive pressure
buildup in the opposite componenthose and fittings.
Operation
10. Ensure pump air pressure and main air valve
are
closed.
Pressure Relief Procedure
i'
11. If you suspect that the nozzle or hose is com-
INJECTIONn
pletely clogged, or that pressure has not been fully
relieved after following the steps above:
m w
The system pressure must be manually
relieved to prevent the systemfrom
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious
injury. To reduce the risk of
an injuryfrom iniection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure if the
spray tiplnonle clogs and whenever you:
are instructed to relievethe pressure,
stopspraying,
check or service any of the system equipment,
or install or clean the spray tip.
a. Remove
b. Direct the gun into a grounded container and
slowly triggerthe gun.
c.
.
CAUTION
If material is left inthe heaters without fluid movement, the material could "cool? and ruin the Coating
as well as plug the heater. The heaters have a large
3. If the system has heaters, turn the poweroff to the
heaters 10 minutes prior to the completion of the
application.
4.
Flush the system immediately afler completion of
the application.
5.
Disengage the dispensing valvesafety latch.
6.
Hold a metalpart of the dispensing valve firmlyto
the side of a grounded metal pail, and trigger the
dispensing valve to relieve
pressure.
7. Engage the safetylatch.
c
8.
Open the mixer manifold drain valves, having a
container ready to catch
the drainage. Close the
valves immediately.
9.
Use the solvent pump to flush the mixer manifold
solvent valves and fluid line(s)
to the applicator.
and clean or replace plugged compo-
e. Tighten any loosened fittings.
. .
f. Very slowly loosen the nozzle or hose end
coupling and relieve pressure gradually, then
loosen completely. Now clear the nozzle or
hose.
Shut off the feed pump and proportioning pump air
regulators and bleed-type
master air valves.
A
If system is still plugged, very slowly loosen
the fittingat the mix manifold 1/4 turn, allow
liquid to run out until pressureis relieved.
d. Remove
nent
1. Engage the dispensing valve safety latch.
2.
and clean tip from spray gun.
I
Handling Plural Component Fluid
PLURAL COMPONENT FLUID
HAZARD
Be extremely cautious when handling
plural component materials and solvents
used with them. Some are extremely
toxic. See the Toxic Fluid Hazard warnings on
page 5. Read and follow the coating and solvent
manufacturer's safety precautions and warnings.
Wear the proper protective clothing, eye protection,
gloves, and clean air breathing apparatus as
prescribed by the fluid manufacturers recommendations, O.S.H.A.regulations and as approved by
N.O.I.S.H. for the chemicals being used.
Observe the Pot (Workable) Life Limit
Flush themixed fluid out of the mixer, dispensing lines
and equipment before it hardens. Flush the complete
system when necessaryto prevent the fluids from
hardening in the equipment and hoses. Check thefluid
manufacturer's instructions for fluid sheif life, and flush
the entire system before this time is reached. Flush the
system with a compatible solventas explained on
page 19.
308986
21
Operation
Fill Throat Packing Nuts
Keep each displacement pump throat packing nut(JJ)
filled with Graco IS0 Pump Oil to help prevent fluid
from drying on the displacement rod and damaging the
pump packings. See Fig. 16.
VeriQ compatibility ofthe pump oil with the fluids being
used in the pumps. During operationvery small
amounts of this fluid are dragged past the seals and
into the pump.
Monitor Material Supply
A
Fig. 16
I
I
mas7
CAUTION
Establish a rigidsystem for monitoringthe material
supply to prevent the pumps from running dry.
A
sudden lack of materialin one pump may cause
many system problems, including air entrapment,
spitting of the fluids, fluid "crossovers", pump
damage, downtime, and added system stresses.
Check Drainage Bottles and Hoses
1
1
INJECTION HAZARD
To reduce the riskof serious injury and property
damage, regularly check and clean
the drain hose
and bottle for the automatic pressure relief
valve.
If material is allowed to dry in and clog the drain
hose, the automatic pressure relief valve may not
fully release thefluid pressure if it opens or may
cause the drain hoseto burst.
Check the drain hose and bottle(38) at the start of
each shift, and whenever thereis an imbalance of
material, to see if the automatic pressure drain valve
has released material into thebottles. Clean the hose
and bottle as needed. Regularly check the drain hose
for cuts, leaks,or bulges and replacedamaged components before usingthe system. See Fig. 17.
22
308986
Never allow the feed pump or solvent pump containers
to run dry. A dry container allows airto be pumped into
the system and causes incorrect proportioning.A dry
pump will quickly accelerate to a high speed, and may
damage itself and the other displacement pump
because it causes a pressure rise inthe other pump. If a
supply container becomes dry,stop the pump immediately, refill thecontainer, and primethe system again.
Be sure to eliminate all the air fromthe system before
continuing the application.
NOTE: The pump runaway valve mentionedon
page 11 of the Installation section shutsoff the pump if
the pump speed accelerates quickly.
(:,
Operation
e. When material flows from drain valves, close
P2).
drain valves IP1
\. - and
-
Startup
i
i
~~~~
f.
INJECTION HAZARD
To reduce the risk
serious
of
injury,
warm
up.
follow the Pressure Relief Procedure
on page 21 whenever you are instructed
to relieve the pressure.
I
Never exceed themaximum air and fluid working
pressure of the lowest rated componentin your
system. See Equipment Misuse Hazard, page 3.
~
If equipped with heaters, turn power on to
heaters and wait5 minutes for heaters to
g. Turn proportioning pump air regulator up to
start pump.
h. Trigger gun, with tip removed, into waste
container until material flows smoothly with no
air pockets.
I. Install full containers of resin and hardener at the
feed pumps.
i.
Close applicator valve and set safety latch.
j.
Place tip onapplicator.
2. To mime the svstem:
a. Open material valve. See Figure 14 and
Figure 15 (Ql).
b. Start feedpumps.
C.
k. Release trigger safety and spray a test pattern.
I.
Open mix manifold valve (KKJ Handle down.
d. Open drain valves (PI and P2) until material
flows from both sides. Increase feed pressure
Up to 100 psi.it required to get material to flow.
Increase main proportioner pressure and test
pattern. Repeat this processuntil an acceptable patternis achieved.
m. Note the pressures while spraying and material
temperatures if heaters are used.
KEY
Bleed-type
master air vdve
A l Hardener feed pump
A2 Resinfeedpump
A3 Proportioningpump
E Pumpairregulator
El Hardener
feed pump
A
Fig. 18
J
E.? Resin
feed
pump
E3 Proportioningpump
Fluid
pressure
gauge
J1 Proportioning
pump
intake
J2 Proportioningpumpoutlet
H
Proportioning
pump
N Mixermanifold
S Dispensing
valve
V Fluid
strainer
''
02913
308986
23
Operation
3. Turn on the heaters, if used, and allow them to
warm up for10 minutes.
4. Open the mixer manifold (N) and trigger the
dispense valve(S).
5. Open the feed pump air valves (Al,A2). Adjust the
air regulators(El ,E2) just enoughto start the
pumps operatingslowly.
6. Open the proportioning pump air valve(A3) and
slowly open the regulator(E3) to start the proportioning pump.
7. Set the air pressure to the feed pumps at no more
than 25% of proportional pressureat the fluid
outlets. Use the gauges (JI) to monitor this pressure. Higher pressures may prevent the proportioning pump inlet ball checks from setting properly.
8. Set the air pressure to the proportioning pump (H)
to obtain the required fluid pressure. Refer to
Configurator Product Order Form 309002
.
Checking Mix Ratio
i
INJECTION HAZARD
To reduce therisk of serious injury,
follow the Pressure Relief Procedure
on page 21 whenever you are instructed
to relieve the pressure.
~~~
~
NOTE: Since this is a fixed ratio system, you typically
do not haveto check the mix ratio.
If the mixed fluid does not cureor harden properly,
check the ratio of resinto hardener.
1. Flush the mixer manifold: see Step 11, page 19.
2. Follow the Pressure Relief Procedure, page 21.
3. Open the mixer manifold
(N),handle (KK)up.
9. While triggering the dispensing valve, check the
fluid outlet pressure gauges(J2)and make noteof
the pressures indicated.Check the gauges
frequently during operation. Thesenotes will help
to analyze any problems that may occur since a
be
change in displacement pump performance will
indicated by a change in pressure
gauge readings.
4. Set the operating pressure for the pumps. See
Steps.7 and 8 on page24.
NOTE: A quick pressure drop does
occur during pump
stroke changeover, but should remain steadyif the
applicator is not triggered. Pressureloss in a static
state indicates a packingor check valve leak and
should be repaired.
7. Open the hardener side drain valve (P2) about
NOTE: Flush the mixer manifold frequently during the
day’s operation. Follow Step 11 on page 19.
8. Place a grounded metal pail under the drain
valves.
24
308986
5. Release the dispensing valve trigger and engage
the safety latch.
6. Close the mixer manifold (N), handle (KK)down.
three tums. Open the resin side drain valve(PI)
about 1 turn. This prevents the pressure from
building up on the hardener pump, which would
cause the automatic pressure relief valveto open.
Operation
9. mixer
manifold.
Open
the
15.
valves
drain
(P1,PZ).
Close
the
10. While observing the pump outlet gauges (J2),
adjust the resin and hardener drain valves ,P2)
(P1
until the gauges show your normal operating
pressure.
NOTE: The pressure must be within20% of the original spraying pressure to get a usable test.
11. Close the mixer manifold. Put a separate sampling
valve.
drain
each
container
under
12. Open the mixer manifold to draw a sufficient
sample.
13. As you closethemixermanifold,checkthepumpP1
outlet gauges (J2) again to make sure they areat
your normal operating pressure.
14. If the fluid pressure is not within 20% of the normal
operating pressure, flush the mixer manifold again
and take another sample.If the sample ratio is
incorrect, refer to the Troubleshooting chart on
page 27. If the ratiois correct, the problemis with
component.
system other
J2
KK
N
P2
Fig. 19
i:
i
308986
25
Shutdown and Care of the System
A
A
Arrow must point down.
Apply tape and sealant to threads
INJECTION HAZARD
To reduce the risk of serious injury,
follow the Pressure Relief Procedure
on page 21 whenever you are instructed
to relieve the pressure.
System Shutdown
To shut the system down, shutoff the air to all pumps,
trigger the dispensing valve into a grounded metal
waste container. Close the mixer manifold valves.
Flush all the mixed fluid out of the mixer manifold,
hoses and dispensing equipment. See page 19. Then
foilow the Pressure Relief Procedure, page 21,
Pump Inlet Strainer Cleaning
If the fluid pressure from the feed pumpthe
to proportioning pump cannotbe maintained on the proportioning pump intake gauge(JI), check and cleanthe
strainer 0.See Fig. 18, page23.
1. Relieve all feed pump pressures.
2. Remove “Y” strainer, clean, and replace.
3.
Restart feed pumps andcheck for open inlet feed
lines.
Clean Static Mixer
m.
Visually inspect the static mixer(G)
Replace
the static mixer if cloggedor damaged. See Fig. 20.
1. Follow the Pressure Relief Procedure on page 21.
2.
Remove the hose (H) from the static mixer (G).
3. Unscrew the static mixer (G) from the mix manifold.
4.
Push the mixer element out of the static mixer by
inserting a wooden dowel
at the adapter (I)end.
Clean all parts witha compatible solvent, and
reassemble.
5. Install the static mixer (G). The arrow on the static
mixer must pointdown. Apply tape and sealantto
the threads of the static mixer.
26
308986
Fig. 20
835zA
Pump Throat Packing Nuts or Cup Care
Keep the throat packing nuts or cup(JJ) filled with
appropriate lubricant and check
the tightness ofthe
packing nut weekly. See Fig. 21.
Always follow the Pressure Relief Procedure, page
21. before adjustingthe packing nut. The packing nut
should be tight enough
to prevent leakage; no tighter.
Too tight an adjustment causes the packings
to bind of
wear prematurely and leak.
i.
Troubleshooting
INJECTION HAZARD
To reduce therisk of an injury from
injection, splashing fluid, or moving
parts, follow thePressure Relief Procedure on page 21 if the spraytiplnoule clogs and
whenever you:
0
are instructed to relieve thepressure,
stopspraying,
check or sewice any of the system equipment,
or install or clean.the spray tip.
This chart uses the proportioner
gauges to determine pump malfunctions.
Faulty manifoldcheck valves can
mask pump cylinder problems.
Always keep these valves operating properly.
including amputation, from moving parts
The chart belowis specific to the air motor and pump.
with the
Refer to the other instruction manuals included
system to troubleshoot individual components.
TROUBLE AREA:
RESIN PUMP LEAKAGE
TROUBLE AREA:
HARDENER PUMP LEAKAGE
1. THROAT PACKING
2. PISTON PACKING
3. PISTON BALLCHECK
1. THROAT PACKING
2. PISTON PACKING
3. PISTON BALL CHECK
Observe the gauge readings during the stroke direction indicated
by the boldarrow, and
immediately after closing the
manifold.
Flush and clean thefilter screens.
IiARDENEf
PUMP
Trigger the applicator and stop
the proportioner in the up position.
If gauges hold equal pressure,
this side of the systemis operating properly.
If pressure fallsfaster on one
gauge, service on that side
is
required. RepaidReplace ball
check or piston packing or
throat packing of thepump.
FALLING
IROUBLE AREA:
RESIN PUMP LEAKAGE
TROUBLE AREA:
HARDENER PUMP LEAKAGE
1 . THROAT PACKING
I. THROAT PACKING
2. FOOT VALVE BALL CHECK
2. FOOT VALVEBALL CHECK
Trigger the applicatorand stop
the proportioner in the down position.
If pressure falls fasteron one
gauge, service on that side is
required. Repair/Replace throat
packing or inlet foot valve of the
pump.
3ISING
ww
FALLING
308986
27
Troubleshooting
Solution
Cause
System will not run or
stops whilerunning.
Air pressure or volumetoo low.
Increase, check air compressor.
Closed or restricted air line or air valve.Open or clean as required.
Fluid valves closed.
Open fluid valves.
Clogged fluid hose.
Replace fluid hose.
Air motor worn or damaged.
Service air motor. See instructions
in
separate manual 306-982.
Displacement pump stuck.
Service pump. See instructionsin separate manual 307-944 or 684-004.
Fluid containers areempty."
Check often - keep filled.
Air in fluid lines.**
Purge, check connections.
Displacement pump parts worn or damaged.
Service pump. See instructionsin separate manual 307-944or 684-004.
Dirty, worn or damaged resin pump piston valve.
Clean, service pump. seeinstructions
in separate manual.
.Worn or damaged resin pump piston
packings.
Replace.
Pump operates but resin
output pressure drops during downstroke.
Dirty, worn or damaged resin pump
intake valve.
Clean, service pump. See instructions
in separate manual 307-944 or
684-004.
Pump operates but resin
output pressure drops
during both strokes.*
Dirty, worn or damaged resin pump piston valve.
runs erratically.
Clean, service pump. See instructions
in separate manual 307-944 or
684-004.
Fluid supplylow.*
Refill or change container.
Dirty, worn or damagedresin pump intake valve.
Clean, service pump. See instructions
in separate manual 307-944 or
684-004.
Worn or damaged hardener pump piston packings.
Replace.
drops during upstroke.*
Pump operates but hardener output pressure
drops during downstroke.*
Ditly, worn or damaged hardener pump Clean, service pump. See instructions
in separate manual 307-944 or
intake valve.
Pump operatesbut hardener output pressure
drops during both
strokes.
Dirty, worn or damaged hardener pump Clean, service pump. See instructions
in separate manual 307-944or
intake valve.
Relief valve openstoo
soon or will not close.
684-004.
684-004.
Fluid supply low.*
Refill or change container.
Loose packing nutor worn throat packings.
Tghten, replace.
Relief valve needs adjusting or is dam- Adjust, service pump. See instructions
in separate manual 307-944 or
aged.
684-004.
* Fluid ratio will be wrong.
* Purge all air out of the system before proportioning the fluids.
28
308986
Service
- Displacement Bump
INJECTION n m m
To reduce the risk of serious injury,
follow the Pressure Relief Procedure
on page 21 whenever you are instructed
2. Three DisplacementPump Models On&
Unscrew the swivel union (33) from the bottom of
the center displacement pump. Unscrew the swivel
unions (126) fromthe outer displacement pumps.
Remove the supply manifold (125) fromthe outer
pumps. Unscrew the straight union (39) from the
center displacementpump. See Fig. 23.
Removal and Replacement
Thoroughly flush the system with a solvent which is
compatible to the fluid being pumped, then follow the
Pressure Relief Procedure on page 21. The Flushing
procedure is on page 19.
N O T E Try to always stap the pump at the bottom of
the stroke after flushing, before any maintenance, or at
any extended shutdown with the material
in the pumps.
Stop the pump at the bottom of its stroke.
A
Fig. 22
33
CAUTION
If you are changingto a different typeof fluid, completely clean allof the equipment and hoses, making
sure that no fluid remains
in anv Dart of the svstern.
Remove the fluid outlet hoses from the displacement
pumps.
1. Two Displacement Pump Models Only
Unscrew the swivel unions (33) from the bottom of
the displacement pumps. See Fig. 22.
"
Fig. 23
308986
29
Service
- Displacement Pump
Disassembly
1. Remove the locknuts (113) from the top of the
yoke (114) of the two outer displacement rods. See
Fig. 24. Unscrew the outer locknuts (122) from the
top of the tie plate (121) on thetwo displacement
pumps. Use a screwdriver and hammer to loosen.
111
115
122
NOTE: Thetie rods (111) shown in Fig. 24 are
removed from thetie plate (121) for clarity only and
do not require removal.
2. Remove the two outer pumps from the tie plate.
Remove the washers (115) from the rodsof each
Pump.
(72-91
N-m)
123
121
3. Three Displacement Pump Models Only.
Using a wrench on the flats
of the center pump's
displacement rod, screw the rod out of the
yoke (114). See Detail B in Fig. 24. Remove the
pump from the yoke(114) then the washer (115)
from the rod on the pump.
4.
Refer to the appropriate instruction manual for
servicing the displacement pump.
Reassembly
1. Three Displacement Pump Mode& On&
Slide the center displacement pump
rod through
the tie plate (121), center locknut (123), and wash3. Move the air motor to the bottom of its stroke.
er (115). Thread the displacement rod into the
Check for movement of the air motoryoke at each
yoke (114) by turning the complete cylinder. Use a
displacement rod. Wahthe rods centered, tighten
wrench on the flats of the displacement rod for final
the
locknuts (113)securely and torqueto 53-67 fttightening. Torque to 53-67 ft-lb (72-91 Nm).
Ibs
(72-91
Nm).
Push the cylinder up into place in the tie plate and
install the center locknut (123).
2. All pumps
Slide the outertwo displacement pump rods
through the tie piate (121), outer locknuts (122),
and washers (115). Install the locknuts (113)
loosely on the displacement rods. Push the cylinders up into placein the tie plate and install the
outer locknuts (122).
30
308986
4. Tighten the throat packing nut just enough to
prevent leakage, no tighter.
5. Reconnect the swivel unions to the pumps. Hold
the intake valve(C) steady with a wrench to prevent it from turning.
308986
31
Graco Standard Warranty
Graco warrantsall equipment manufactured by Graco and bearing its be
name
freefrom
to defectsin material and workmanship
onthe
date of sale
by an authorized Graco distributor
tothe original purchaser for use.
Witheexception ofany special, extended, or limited
warrantypublishedbyGraco,Gracowill,foraperiodoftwelvemonthsfromthedateofSale,repairorreplaceanypartoftheequipment
determined by Graco to bedefective. This warranty applies only when the equipment
iS installed. operated and maintained in accordance with Graco's written recommendations.
(
This warranty doesnot cover, and Graco shall not
be liable for general wear tear,
and or anymalfunction. damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequateorimproper
maintenance, negligence. accident, tampering,
orsubstitution of non-Graco component parts.
Nor shall Gracobe liable formalfunction. damage or wear causedby the incompatibilityof
Graco equipment with structures, accessories, equipment or materials not supplied
Graco,
by or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warrantyis conditioned upon the prepaid return
of the equipment claimed
to be defective to anauthorized 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 returnedto the original purchaser transportation prepaid. If inspection
ofthe equipment does not disclose any defect
the costs of parts, labor, and
in materialor workmanship. repairs wil be madeat a reasonable charge, which charges may include
transportation.
THIS WARRANN IS EXCLUSIVE, ANDIS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANN OF MERCHANTABILITYOR WARRANlY OF FITNESS FOR A PAFiTlCULAR PURPOSE.
no other
Graco'ssoleobligation and buyer's sole remedy
anyforbreach ofwarranty shall
beassetforth above. The buyer agrees that
remedy (including,but notlimited to, incidental
or consequential damages for lost profm. lost injury
sales,to person or property, or any
be brought withintwo (2) years ofthe
otherincidental or consequential loss) shall beavailable. Any actionfor breachofwarranty must
date of sale.
Graco makes no warranty,
and disclaims all implied warranties of merchantability andfimess for a particular
purposeinconnection with
accessories, equipment, materialsor 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,
any. oftheir
if manufacturer. Gracowill 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 resultingfrom Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether
to a due
breach of contract,
warranty.
breach of
FORGRACOCANADACUSTOMERS
The parties acknowledge that they have required that the present document,
as allasdocuments,
well
notices and legal proceedings
entered into. given
or instituted pursuant hereto
or relating directlyor indirectl'! hereto, be drawn up in English. Les parties reconnaissent avoir convenu que
la redaction du presente document sera
en Anglais.ainsi que tous documents, avis et procedures judiciaires
executes, donnes ou intentes a la suite de ouen rapport, directement ou indirectement; avec 18s procedures concernees.
Graco Phone Number
TO PLACE AN ORDDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1-800-367-4023 Toll Free.
All W'tten and visual data containedin this document reflects the latest pmduct
infonation available at the time of publication.
Graco reserves theright to make changesat any time without notice.
Sales Offices: Minneapolis, Detroit
Foreign Offices: Belgium, Korea,Hong Kong, Japan
GRACOINC.
P.O. BOX 1441 MINNEAPOLIS, M N 55440-1441
www.graco.com
PRINTED IN USA 308986 Rw. A March 1999
308986
32
j
'.

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