Graco 334135B User's Manual
Contents
1. 23 SOLD ane pt Yeeros ee seuss t dices 26 Piston Position Calibration 26 Prime the Dispense Head 28 Phasing Adjustment lusu 29 Adjust Dispense Valve Snuff Back 31 Adjust Open Dispense Valve ODV Timing 32 Operation jj nai oom o e vs 33 Se es siel B dreds 33 Pressure Relief PIOGOQUEO iacu di sia ae ae ee we ee eae 33 Shutdown eee 34 Maintenance lllelerens 35 See tienes quoda PP aad uoti nd 35 Clean the Pump Shafts 35 Disassemble and Clean the Dispense Head 35 Install Upgrade Token 36 Troubleshooting lesse 37 LCM Error Codes lees 39 FIGDdIE uocis 2d a oa ele ed 40 HydraCheck Kit Installation 24VV336 40 Air Cylinder Rebuild Instructions 42 Rear Pump Rebuild Instructions 44 Piston Cylinder Replacement Kit Installation 46 Check Valve Rebuild Kit Installation 47 Parts 2ukdescu a c ccm toa ic Ro Ma t v A Da 48 Fixed Ratio Base sess 48 Pump Sub Assembly 248053 50 Fixed Ratio Drive Block Assembly LCO107 52 Air Cylinder 24V933 and 24V934 53 Fixed Ratio Frame Sub Assembly LCO290 54 Schemall6S iau due eru chee aie ee 56 Electrical Schematics 56 Pneumatic Schematic 58 Appendix A LCM Icon Overview 602. 1 Relieve pressure See Pressure Relief Procedure 6 Remove the incoming power bracket from the page 33 machine by removing the four attachment screws 7 q 0 p 2 Shut down the machine See Shutdown page 34 3 Disconnect the pressurized air input hose 4 4 Loosen machine shield screws f es J NOD 5 Remove the machine shield 42 334135B Repair 7 Use an open end wrench to remove all hex nuts the bolts to 350 in Ib 39 5 Nem in a crisscross pat connecting the piston rod to the drive block tern 8 Remove the four screws that attach the cylinder rod end block to the frame Access the screws through the four holes in the blind end block using a long allen wrench 9 Partially remove the air cylinder by pulling on the cylinder from the back of the machine until the air lines at the elbow fittings can be seen 10 With the cylinder partially removed disconnect the airlines at the air cylinder elbow fittings 21 Insert the cylinder rod through the hole in the rod 11 Finish removing the air cylinder end cylinder block and base trame 22 Reinstall the four screws that attach the cylinder rod 12 On a bench disassemble the air cylinder by remov end block to the frame ing the four long screws that connect the two cylin der blocks 23 Reinstall the hex nuts to the cylinder rod and torque Clean and Inspect the Parts to 100 ft lb 135 Nem 13 Inspect the cylinder tube and piston for scratches
3. Appendix B LCM Run Screen Overview 62 Appendix C LCM Setup Screen Overview 64 KS ariani neue a aa e a S 65 Nylon and UHMW Piston Replacement Kits 65 Recommended Spare Parts 66 DIMENSIONS 6 62055 tek dios ees te ele ee es 67 Technical Data 5 e x REOR ee 69 Graco Standard Warranty 70 Graco Information 70 334135B Models MD2 Valve Air Motor Required Machine Maximum Ratio in cm Line Operation Working Voltage Voltage Pressure psi MPa bar LN or 100 240 V a E E sod BB BE TNT M lg 50 Watts 11 4 50 Watts 1 wi Related Manuals MD2 Dispense Valve Manual PE 312185 MD2 Valve Instructions 312394 PR70 and PR70v Feed Systems Instructions Parts 334135B Models Maximum Air Inlet Pressure psi MPa bar 100 0 7 7 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbols refer to procedure specific risks When these symbols appear in the body of this manual or on warning labels refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding s
4. assembly LCO0120 only 901b 255208 HANDLE 2K dispense valve electric 1 902 121198 CORD euro male 4 pin 3 wire 6 m 1 Series A Handles only 123660 CORD euro male female 6 m 1 Series B Handles only 903 120953 CONNECTOR splitter 1 1 See MD2 manual for dispense valve and dispense valve handle parts information 10 334135B Lever Actuated MD2 Valves LC0121 and LC0123 Assembly LC0121 Shown Ref Part Description Quantity 1101 LCOOO5 VALVE assembiv 1 1 lever electric 1 assembly LCO121 only LCOOO7 VALVE assembly 10 1 lever electric 1 assembly LCO123 only 1101a 255249 LEVER 2K dispense valve 1 1101b 25518171 VALVE dispense 10 1 soft seats 1 assembly LCO123 only 255179T VALVE dispense 1 1 soft seats 1 assembly LC0121 only 1102 121198 CORD euro male 4 pin 3 wire 6 m 1 Series A Handles only 123660 CORD euro male female 6 m 1 Series B Handles only 1103 120953 CONNECTOR splitter 1 1 See MD2 manual for dispense valve and dispense valve lever parts information 334135B Hecommended Parts 1103 1102 ti12441a 11 Hecommended Parts Mixers 1302 ti12442a X A gn I SS ig qu 1303 1301 Assembly LC0061 Shown 334135B Hecommended Parts Reference Number and Description
5. 2 1i 15K8M4 ROD piston 2 112 15K828 WASHER housing seal 2 113 15K895 HOUSING check valve 1 2 114 lCO093 KIT rebuild valve check 2 Included in kit LC0094 NO DO N NO PO Check Valve Assembly LC0093 a 114 3 Chamfer ais A AN The side of the seat with an outside diameter chamfer must point away from the ball FIG 17 Ref Part Description Quantity 114 1 105445 BALL 0 5000 1 114 2 121084 SPRING 1 114 3 15D312 BUSHING ball guide 1 114 4 196832 SEAT lapped 1 334135B Parts 51 Parts Fixed Ratio Drive Block Assembly LC0107 206 3 1 Apply grease part 115982 to all internal parts A Tighten retaining nut until alignment rod 202 cannot be moved Loosen retaining nut until alignment rod can move side to side with no in and out movement A Torque to 64 in Ib 7 2 Nem Fic 18 Ref Part Description Quantity 201 120891 SCREW set socket cone point 2 202 15K801 ROD alignment 2 203 15K802 RETAINER nut 2 204 15K805 BLOCK drive 1 205 15K868 WASHER female male modified assembly 2 206 Mi 84 0130 27 11 LABEL warning pinch point 1 A Heplacement Danger and Warning labels tags and cards are available at no cost 52 334135B Parts Air Cylinder 24V933 and 24V934 NOTICE The four long screws 303 that attach the two drive blocks 309 310 must be tightened
6. 24 Install the three screws that attach the solenoid Replace if necessary valves to the blind end block Torque to 41 in lb 4 6 Nem 14 Using a clean dry cloth remove any grease from the inside of the tube the outside of the piston and 25 Reinstall the control bracket the cylinder rod y 26 Reconnect the air line 15 Remove the two cylinder block o rings from the blocks and replace Prepare Machine for Operation 27 Reattach the incoming power bracket by reinstalling 16 Remove the piston o ring and replace the four attachment screws 17 Remove the cylinder rod from the rod end block 28 Reconnect air input hose 18 Remove the rod o ring from the rod end block and 29 Operate the machine and ensure there are no air replace leaks found 19 Liberally apply high temperature lubricant grease part 115982 to the inside of the tube the outside of the piston all the o rings and the cylinder rod 31 Install machine shield screws 30 Install the machine shield Re Assemble the Air Cylinder 32 Calibrate the machine NOTICE In the following step the long screws must be tight ened in a crisscross pattern Failure to do so may result in air cylinder damage 20 Reinstall the four long screws that attach the two drive blocks by finger tightening them Then torque 334135B 43 Repair Rear Pump Rebuild Instructions The pump shaft is installed coated with Krytox grease Wear protective gloves
7. 94 1009 98 BEEN LCO811 1 2 in x 120 in 16C534 94 0150 S 25 94 1009 98 ss LCO812 1 2 in x 180 in 16C535 94 0150 S 25 94 1009 98 ia VCH LC0403 1 2 in x 30 in 16D271 94 0150 S 25 16C399 Oe LC0404 1 2 in x 120 in 16D276 94 0150 S 25 16C399 ET LC0405 1 2 in x 180 in 16D277 94 0150 S 25 16C399 OO LC0813 3 4 in x 120 in 16C544 94 0153 S 25 94 1083 98 a LC0814 3 4 in x 180 in 16C545 94 0153 S 25 94 1083 98 TO LC0406 3 4 in x 120 in 16D286 94 0153 S 25 94 1083 98 Ss LC0407 3 4 in x 180 in 16D287 94 0153 S 25 94 1083 98 SSeS Quantity 1 1 1 1 High pressure hoses 3500 psi 24 MPa 241 bar 8 334135B Hecommended Parts 334135B 19 Hecommended Parts Piston Package D 603 ay 606 N 601 606 ti12438a AN Arrow on cylinder must point to the o ring 606 on the right Nylon Piston Stainless Steel Metering Tube Assemblies Reference Number and Description 601 602 6031 604 605 606 Piston Tube Nylon Ring support Package pump Piston Washer piston Screw O ring LC1080 LCCO80 LCBO80 LC1100 166100 LCB100 9 MC 9 LC1120 LCC120 LCB120 LC1140 LCC140 LCB140 LC1160 LCC160 LCB160 LC1180 LCC180 LCB180 LC1200 LCC200 LCB200 LC1220 LCC220 LCB220 15M099 15K887 LC1240 LCC240 LCB240 LC1260 LCC260 LCB260 LC1280 LCC280 LCB280 LC13
8. Manually Move the Piston Drive Block a Perform Pressure Relief Procedure on page 33 b Remove the machine cover c With no air pressure in the system manually push the piston drive block until the piston engages the cylinder and resists movement A number from 2000 to 2400 will be displayed NOTE If a number outside of this range is displayed ensure the air cylinder air line connections are not switched and that the linear position sensor is properly installed 15 Ensure there is no material in the waste container under dispense valve The piston block moved too far and caused material to be dispensed if there is material in the waste container Go back to step 14 if the piston moved too far 334135B Setup 16 Press the Enter button Kai to accept the value or press the Abort Cancel button ez to keep the previous value Prepare Machine for Operation 17 High light the Retract Piston button 4 18 Press the Dispense Request button 19 Open the vented ball valve to enable system pres sure The piston will fully retract when the system is pressur ized To avoid injury ensure the machine shield is installed 20 Adjust the system air pressure regulator to increase air pressure to standard operating pressure for your application 21 Navigate to the Shot Mode Screen or Operator Mode Screen 27 Setup Prime the Dispense Head 9 Select a large size shot 10 Hold a waste con
9. Press the Enter but ton EE to accept the new operating mode O E Fic 9 Disabled Mode 334135B Operation Pressure Relief Procedure A Follow the Pressure Relief Procedure whenever you see this symbol TENE This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashing fluid and moving parts follow the Pressure Relief Procedure when you stop spraying and before vra cleaning checking or servicing the equipment 1 Place a waste container below the dispense valve 2 Navigate to the Maintenance Mode Run Screen 3 Press the Shot Mode Designation button ar on the Maintenance Mode Run Screen to relieve chemical pressure Press the Shot Mode Designa tion button Sef again to close the dispense valve 4 Press the Machine Disable Mode button 5 Close the vented ball valve 33 Operation Shutdown If the machine is to remain idle for an extended period of time perform the following steps 1 If installed remove static mixer from the end of the dispense valve 2 Place a container below the dispense valve and activate a small shot to flush mixed material out of the valve 3 Relieve pressure See Pressure Relief Procedure page 33 4 With a clean rag and cotton swabs clean the end of the dispense valve 5 Install the nightcap on the dispense
10. is ready and operational Continuous Flashing System is starting up or system is being programmed Continuous Flashing with Pause Indicates an error is active Refer to LCM Error Codes page 39 Flash Once with Pause System is inactive Component Identification LCM Screen Navigation For screen overview refer to Appendix B LCM Run Screen Overview and Appendix C LCM Setup Screen Overview starting on page 62 Splash Screen Disable Mode Screen Maintenance Mode Shot Mode Screen Run Screen Operator Mode Screen Position Calibration Screen Phasing Shot Calibration t 1 874 3821 XXXX are Setup Screen Pass Dispense Amount Pro Open Dispense Valve word Set Clear Screen hibit and View Cycle Position Calibration 1 B235 v1 01 8087 1234 334135B Component Identification 334135B 9 Hecommended Parts Recommended Parts Dispense Valve Standard Dispense Valves 255179 and 255181 See MD2 manual for parts information Gun Mounted MD2 Valves LC0120 and LC0122 901a Assembly LC0120 Shown uude Ref Part Description Quantity 901 L CO0006 VALVE assembly 10 1 gun electric 1 assembly LCO122 only L CO0004 VALVE assembly 1 1 gun electric 1 assembly LCO0120 only 901a 2551817 VALVE dispense 10 1 soft seats 1 assembly LCO122 only 255179f VALVE dispense 1 1 soft seats 1
11. 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 supplyi
12. two screws that hold the pump collar in place 11 Remove the pump collar from the pump housing 12 Slide the pump bearing housing away from the pump housing to remove 13 Remove rear pump components from the pump bearing housing Clean and Inspect the Parts 14 Using a clean dry cloth remove any existing grease from the bearing housing 15 Apply new high temperature grease lubricant part 115982 to the inside of the pump bearing housing and the new rebuild components Assemble the Rear Pump Assembly 16 Install the new rebuild kit components into the bear ing housing NOTICE Be careful when installing the seal Ensure there is masking tape on the threads of the piston rod and that the open side of the seal faces the piston rod when it slides onto the rod 334135B Repair 17 Apply one layer of thin masking tape over the male threads of the pump shaft that mates with the drive block This will prevent the threads from damaging the seal 18 Slide the pump shaft through the hole in the bearing housing 19 Align the bearing housing in position next to the pump housing 20 Install the pump collar over the bearing housing 21 Attach the pump housing using the two screws and torque to 350 in lb 39 5 Nem 22 Remove the masking tape from pump shaft 23 Install the pump shaft lock nut onto the pump shaft 24 Connect the pump shaft to the drive block alignment rod Screw the shaft completely int
13. 00 LCC300 LCB300 LC1320 LCC320 LCB320 120933 120874 LC1360 LCC360 LCB360 LC1400 LCC400 LCB400 LC1440 LCC440 LCB440 LC1480 LCC480 LCB480 M100 IPSOS LC1520 LCC520 LCB520 LC1560 LCC560 LCB560 LC 1600 LCC600 LCB600 LC1640 LCC640 LCB640 LC1720 LCC720 LCB720 LC1800 LCC800 LCB800 15M101 15K890 LC1880 LCC880 LCB880 LC1960 LCC960 LCB960 Quantity 1 1 1 1 1 2 20 334135B Hecommended Parts UHMW Piston Stainless Steel Metering Tube Assemblies Reference Number and Description 601 602 6031 604 605 606 Piston Tube UHMW Ring support Package pump Piston Washer piston Screw O ring LC2160 LCC160 LCA160 LC2180 LCC180 LCA180 LC2200 LCC200 LCA200 LC2220 LCC220 LCA220 15M099 15K887 LC2240 LCC240 LCA240 LC2260 LCC260 LCA260 LC2280 LCC280 LCA280 LC2300 LCC300 LCA300 LC2320 LCC320 LCA320 LC2360 LCC360 LCA360 LC2400 LCC400 LCA400 120933 120874 LC2440 LCC440 LCA440 LC2480 LCC480 LCA480 SMICO is LC2520 LCC520 LCA520 LC2560 LCC560 LCA560 LC2600 LCC600 LCA600 LC2640 LCC640 LCA640 LC2720 LCC720 LCA720 LC2800 LCC800 LCA800 15M101 15K890 LC2880 LCC880 LCA880 LC2960 LCC960 LCA960 Quantity 1 1 1 1 1 2 1 Forcustom piston packages washer 603 part num ber will change by piston size as follows For piston sizes 80 100cc 15M089 For piston sizes 101 159cc For piston sizes 160 285cc Fo
14. 101 15K890 LC3880 LCG880 LCA880 LC3960 LCG960 LCA960 Quantity 1 1 1 1 1 2 1 Parts 55 Schematics Schematics Electrical Schematics Lj L LCM 245065 2 45 ON 466178 25 12 3 4 5 6 7 8 9 10 ff 12 13 144 15 6 17 18 19 20 A 22 23 24 25 RN 24V942 e E HARNESS EX ne ABC DE FG De H J K LM Power Jack 8 24 VDC Power dash 90 246 VAC FiG 21 Electrical Schematic 56 334135B Schematics z iem Power Switch uana NI prouajoS 134 prouajoS IKJ AN Solenoid Valve Assy 120900 Through Wall Connector 121612 Optional Foot Switch 255244 Linear Position Sensor LC0234 Fic 22 Electrical Schematic 334135B 57 Schematics DB25 Pin Function number Pin Function Number Description Dispense Valve DV Open Command Position Sensor Feed Existing Pneumatic Schematic 24V941 S 100 Dua PLANT AIR 29 PSIG 38 120897 120922 127773 io de 100 Dua PILOT SOL RET FIG 23 Pneumatic Schematic 58 334135B Schematics 334135B 59 Appendix A LCM Icon Overview Appendix A LCM Icon Overview When the corresponding soft key is pressed the PR70 will exit disable mode and enter
15. 1301 1302 1303 Mixer Mixer Shroud Sleeve Package Description Part No Quantity Part No Quantity 1 Part No Quantity 1 LCO063 3 16 in x 32 60 0206 50 10 94 0884 1 98 LC0077 3 16 in x 32 60 0206 50 50 t L C0084 3 16 in x 32 60 0206 50 250 Jaa LC0061 3 16 in x 32 Luer Lock 16D012 10 16P448 60 0313 97 LC0082 3 16 in x 32 Luer Lock 16D012 50 oe L C0089 3 16 in x 32 Luer Lock 16D012 250 2s L C0057 1 4 in X 24 60 0204 50 10 16P445 L C0078 1 4 in x 24 60 0204 50 50 eee L C0085 1 4 in x 24 60 0204 50 250 E L C0062 1 4 in x 24 Luer Lock 60 0209 50 10 94 0883 M 98 60 0305 97 L C0083 1 4 in x 24 Luer Lock 60 0209 50 50 a LC0090 1 4 in x 24 Luer Lock 60 0209 50 250 LC0058 3 8 in x 24 60 0200 50 10 16P446 LC0079 3 8 in x 24 60 0200 50 50 sgi LC0086 3 8 in x 24 60 0200 50 250 E L C0059 3 8 in x 36 60 0201 50 10 16P447 LCO080 3 8 in x 36 60 0201 50 50 is LC0087 3 8 in x 36 60 0201 50 250 LCOO6O 318 in combo 6010202150 10 16P447 L C0081 3 8 in combo 60 0202 50 50 E LC0088 3 8 in combo 60 0202 50 250 LCO295 1 2 in x 24 60 01 11 1 50 10 94 0885 24 98 LCO296 1 2 in x 36 60 0117 1 50 10 94 0885 36 98 334135B 13 Hecommended Parts Applicator Mounting Mast Mount Controls and MD2 Applicator LC0292 Mast Mount Controls only LC0293 Quantity LC0292 BRACKET LC0293 BRACKET Descripti
16. Instructions 7 XY GRACO PR70e Compact Benchtop Meter Mix and Dispense System EN Use for accurate metering mixing and dispensing of two component sealants and adhesives in fixed ratios Not for use with isocyanate catalyzed materials For professional use only Not approved for use in explosive atmospheres or hazardous locations Hefer to Models page 3 for maximum working pressures Read all warnings and instructions in this manual Save these instructions e Important Safety Instructions PROVEN QUALITY LEADING TECHNOLOGY Contents MOGSIS x Spo E ado elu o RUE d 309 e dip cid Polo a 3 Related Manuals 3 MVAGNINGS 359 2 bae ERA RUE gh Ae wee sees 4 Component Identification 6 Miete MiB MER TE TEE RESTO e tid T 6 Local Control Module LCM 7 LCM Screen Navigation LL 8 Recommended Parts 10 Dispense Valve leere 10 NDO ES pap RR REED OTRO T TOT CU 12 Applicator Mounting ss 14 Air Filter and Ball Valve 24R707 15 High Temperature Grease 115982 15 Footswitch 255244 u 15 TINK es ep ctv aah hs ade nk ae 16 Hose Packages 22 oues hose eA n 18 Piston Package 00 cece eee eee 20 Pump Tube Combination Information 22 Installation vesa nde n 23 GIOURGING i sh reb ia e EC ee stt 23 Machine Installation
17. LIS MN 55440 1441 st USA Copyright 2014 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revised August 2014
18. and cover exposed skin to avoid possible skin irritation on contact Read Krytox MSDS to know the specifc hazards and follow manufacturer s warnings AN Torque to 350 in Ib 40 Nem Rear Pump Assembly e um um mm mm mm mm mm ME EE EM EM EM M M M M ZN Lubricate shaft with Krytox grease prior to insertion Ll into bearing A K 09 n vje oQ ET A Apply thread sealant to threads Do not allow thread sealant to get into seat area A Piston shafts must be installed from this direction Damage to the shaft seal may result if installed from the opposite direction A Fasten in a crisscross pattern mm E NEED O EBD E NEN Ee Or aA NEM E ES E E E UD UD ND eee FiG 12 Prepare Machine for Kit Installation 3 Shut down the machine See Shutdown page 34 1 Drain the pump Empty the tanks Perform shots 4 Disconnect the pressurized air input hose repeatedly until no material comes out of the dis pense valve 5 Remove machine shield screws 2 Relieve pressure See Pressure Relief Procedure 6 Remove the machine shield page 33 7 Disassemble the Rear Pump Assembly 44 334135B 8 Disconnect the pump shaft from the drive block a Loosen the shaft locking nut b Hold the drive block alignment rod stationary with a wrench c Turn the pump shaft with a wrench d Manually push the pump shaft forward to sepa rate the shaft from the drive block 9 Remove the shaft lock nut 10 Remove the
19. applies LCE Piston Size mm2 The items indicated above will be supplied with the kit 334135B 65 Kits Recommended Spare Parts PR70E Part Description Quantity L C0091 3 0 in 7 6 cm Air Cylinder Rebuild Kit 1 L C0092 4 5 in 11 4 cm Air Cylinder Rebuild Kit 1 L CO093 Stainless Steel Ball Check Valve Rebuild Kit 1 LC0318 Carbide Ball Check Valve Rebuild Kit 1 L C0094 Rear Pump Seal Rebuild Kit 2 i High Volume Piston Replacement Kit 1 i Low Volume Piston Replacement Kit 1 16H378 LCM screen protector 1 See Piston Package on page 20 and Nylon and UHMW Piston Replacement Kits on page 65 for kit numbers MD2 Valve Part Description Quantity 255217 Air Cylinder Repair Kit 1 255218 Valve Lube Seal Kit 1 255219 Front Valve Repair Kit 1 66 334135B Dimensions Dimensions Z N i D Id 1 15 5 in 40 cm 4 A UJ PJ WARNING ADVERTENCA MSE EN GARDE 9 0 in 23 cm 25 1 in 65 cm 27 9 in 71 cm 334135B 67 Dimensions 68 334135B Technical Data Technical Data Pump Cycles per 1 L 0 26 gal PR70e US Metric Metering Pump Effective Area 0 124 to 1 49 in per side 80 to 960 mm per side Small Air Cylinder Effective Area 7 07 in 2 4560 mm2 Large Air Cylinder Effectiv
20. cate with mesamoll silicon oil or other compatible lubricant 4 Clean all parts 5 Lubricate all parts with a thin coat of mesamoll sili con oil or compatible lubricant 6 Reassemble the dispense head 7 Reinstall the dispense head on machine 334135B 35 Maintenance Install Upgrade Token This procedure applies to the Local Control Module LCM 1 Disconnect power to the module 2 Remove token access panel Fic 10 Remove Access Panel 3 Press firmly the token into the slot NOTE There is no preferred orientation of the token 4 Restore power to the module The red LED will flash rapidly to signal that software is loading When the red LED stops flashing the software is done load ing 5 Disconnect the power to the module 6 Remove the token 7 Replace the token access panel 8 Restore power to the module 9 Verify new software versions on the Setup Screen Password Set Clear Screen screen Refer to PKE 2903 found at www graco com for the latest software version by utilizing the search box 36 334135B Troubleshooting Troubleshooting Before starting any troubleshooting procedures perform 3 Allow the machine to cool if the machine has a heat the following procedure control option 1 Relieve pressure See Pressure Relief Procedure Try the recommended solutions in the order given for page 33 each problem to avoid unnecessary repairs Verify all circuit breakers swit
21. ches and controls are properly set 2 Disconnect AC power from the machine and wiring is correct Display Module completely dark No power Verify cable is plugged in dispensed from either side Air in material Prime the machine until the air is removed Check valve malfunction Remove clean or replace check valve Piston worn or broken Hemove and replace piston if worn Piston stalled Input air reduced or removed Reconnect input air line to machine Increase air pressure regulator adjustment Mixer blocked Heplace static mixer Open Dispense Valve ODV adjust Readjust the ODV setting to occur ment too late sooner Blocked check valve Remove check valve clean and replace Air cylinder failure Remove air cylinder and reinstall air cylinder parts as necessary Significant material leaking from Pump shaft worn and or shaft seal Hemove pump shaft assembly and pump rear seal worn reinstall rear pump rebuild kit Material dispensed not correct vol ume Machine air pressure has changed since calibration Readjust air pressure regulator to value used when machine was cali brated or recalibrate machine Not enough material in one or more Check tank levels fill and prime as tanks necessary Mixer has slight obstruction Replace static mixer Prime machine Check valve malfunction Remove check valve clean or replace as necessary Piston worn or broken Replace piston 334135B 37 Troubleshooting Pr
22. e Area 15 9 in 2 10260 mm Maximum Stroke Length 1 50 in 38 1 mm Minimum Stroke Length 0 23 in 5 8 mm Air Volume per Cycle 0 12 to 4 3 in 2 to 70 cc 14 3 to 500 cycles varies by piston size Ratios fixed 1 1 to 12 1 depending upon cylinders selected Maximum Fluid Working Pressure 3000 psi 20 7 MPa 207 bar Maximum Air Input Pressure 100 psi 0 7 MPa 7 bar Maximum Cycle Rate 30 cpm Compressed Air Less than 10 scfm typical varies with cycle times Required Line Voltage 100 240 V 50 60 Hz 1 phase 50 Watts Machine Operation Voltage 24 VDC Maximum Operating Temperature Nylon pistons 160 F 70 C UHMWPE pistons 120 F 50 C Noise dBa Maximum sound pressure 82 dBa Inlet Outlet Sizes Air inlet size Fluid outlet size 1 4 in npt f 03 04 06 08 or 12 JIC fittings for 3 16 in 4 8 mm 1 4 in 6 4 mm 3 8 in 9 5 mm 1 2 in 12 7 mm 3 4 in 19 1 mm hoses Materials of Construction Wetted materials on all models Weight All models 303 304 17 4 PH hard chrome Chromex carbide Chem ical Resistant O rings PTFE nylon UHMWPE 120 Ib 55 kg Notes Inhibisok is a registered trademark of the Penetone Corp Sound pressure measured 3 3 feet 1 meter from equipment Sound power measured per ISO 9614 2 334135B 69 Graco Standard Warranty Graco warrants all equipment referenced in
23. e to 1200 in lb 135 Nem LN Torque to 85 in Ib 9 6 Nem FIG 14 334135B 48 Parts Fic 15 Quantity 24V935 PUMP 24V936 PUMP Description assembly 3 0 assembly 4 5 1 2490583 1 248053 MOTOR air 3 0 EE MOTOR air 4 5 FRAME sub assembly 8 121167 SCREW 9 120885 SCREW 10 BRACKET linear sensor A Heplacement Danger and Warning labels tags and cards are available at no cost 334135B 49 Parts Pump Sub Assembly 248053 The pump shaft is installed with Krytox grease Contact with Krytox grease can lead to flu like symptoms The MSDS for this material is available upon request 106 A A 109 102 N 105 N103 104 AN Torque to 350 in Ib 40 Nem A Lubricate shaft with Krytox grease prior to insertion into bearing A Apply thread sealant to threads Do not allow thread sealant to get into seat area Ay Piston shafts must be installed from this direction Damage to the shaft seal may result if installed from the opposite direction A Fasten in a crisscross pattern A Note orientation of u cup Opening should face pump housing 107 FIG 16 50 334135B Ref Pat Description Guy 102 108712 NULRx 2 103 120887 SEAL posipak 3 8x5 8 UHMWPE 2 104 120890 RING retaining JOB 107 15K 86 HOUSING pump 108 178295 CAP end pump 2 109 15K608 COLLAR 0 2 110 15K804 HOUSING bearing ssa
24. ee Piston Package on page 20 and Nylon and UHMW Piston Replacement Kits on page 65 for kit numbers NOTE Ensure that high volume and low volume pump tubes are installed on the correct side of the machine High Volume Low Volume 5 Secure the piston support ring piston and washer to the piston shaft using the piston screw Tighten the piston screw until the screw stops rotating then turn the screw an additional 1 8 turn 6 Lubricate the tube pump o rings Install the tube pump and o rings as shown 24 7 Install the pump cap onto the assembly using the four bolts Finger tighten the bolts then torque the bolts to 350 in Ib 40 Nem in a crisscross pattern Install the Chemical Hoses Install the chemical hoses and tighten to prevent leaks NOTE Ensure that high volume and low volume hoses are installed on the correct side of the machine Install the Hydracheck Kit Perform HydraCheck Kit Installation 24W336 starting on page 40 Install the Tanks Refer to the PR70 and PR7Ov Feed Systems Instruc tions Parts manual for details Install the Dispense Valve and Support Arm if needed Install the dispense valve as necessary to prevent movement Connect the required air lines from the dis pense valve to the machine C Air to Open l Air to Close O 334135B Connect the Footswitch or External Device 9 Connect Pressurized Air Input 8 Install an air inlet bleeding ball va
25. etup or usage of the system can cause electric shock e Turn off and disconnect power cord before servicing equipment e Connect only to grounded electrical outlets e Ensure ground prongs are intact on power and extension cords e Do not expose to rain Store indoors SKIN INJECTION HAZARD High pressure fluid from dispensing device hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment e Do not point dispensing device at anyone or at any part of the body e Do not put your hand over the fluid outlet e Do not stop or deflect leaks with your hand body glove or rag e Follow the Pressure Relief Procedure when you stop dispensing and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses and couplings daily Replace worn or damaged parts immediately POO OD TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury including eye injury hearing loss in
26. h to dispense a very small amount of mate rial 8 Adjust the displayed percentage if more than a cou ple drops of either material was dispensed or if no material was dispensed from both sides e If too much material was dispensed decrease the phasing percentage If necessary use the arrow keys to switch the percentage from posi tive to negative e f nomaterial was dispensed increase the dis played percentage If necessary use the arrow keys to switch the percentage from negative to positive 29 Setup Adjust Phasing 10 30 003 Key ti12389a 001 Piston Shaft 002 Locking Nut 003 Phase Adjustment Screw Watch the dispense valve carefully to observe which material is dispensed first Press the Dispense Hequest button j or the footswitch to dispense material If the materials do not exit the dispense valve at the same time adjust the piston Phase Adjustment Screw 003 as follows e Ifthe A side material exits the dispense nozzle before the B side material eH a Use two 13 mm wrenches to break loose the locking nut 002 from the phase adjust ment screw 003 on the B material side b Hold the phase adjustment screw 003 sta tionary with a 13 mm wrench c Usea 7 mm wrench to turn the piston shaft 001 counterclockwise 1 4 turn or less to move the B piston forward e Ifthe B side material exits the dispense nozzle before the A side material Gs a Use two 13 mm
27. halation of toxic fumes and burns This protective equipment includes but is not limited to e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer De e 4 334135B Warnings d 191 FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail Do not use pail liners unless they are antistatic or conductive Stop operation immediately if static sparking occurs or you feel a shock Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area 334135B EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pres
28. in a crisscross pattern Failure to do so may result in air cylinder damage Refer to page 42 for rebuild instructions 306A AX se oo 302 A D O n 310 306 A NO O 5 303 N NE se TA 307 N AN Finger tighten all 4 bolts prior to wrench tightening For wrench tightening turn each bolt 1 4 turn in a cross pattern until all 4 bolts are torqued to 350 in Ib 40 Nem 307 A i ZN Torque to 1200 in Ib 136 Nem A Coat all sliding surfaces with lubricant part 115982 A Apply sealant tape to npt fittings FIG 19 Quantity 24V933 MOTOR 24V934 MOTOR mtiani air 0 alr is ee 302 O RING PACKING o ring n 308 120800 SCREW 4a 4 304 120881 BEAHNG 1 1 305 12080 9 SCOREW 1 1 306 1209828 O RING 2 p PACKING o ring O 308 TUBE air cylinder 3 0 04 qum TUBE ai cylinder 45 pq 1 O 309 18K791__ BLOCK air cylinder rodend 1 D 1 310 15K792 BLOCK air cylinder bindend 1 1 311 15K708 PISTON 1 77777 55K94 PISTON 1 O T Available in kit LCOO092 Available in kit LC0091 334135B 53 Parts Fixed Ratio Frame Sub Assembly LC0290 404 AN Torque screws to 85 in lb 9 6 Nem ZA Lubricate linear slide 407 Fic 20 Ref Part Description Guanty 120599 PIN dowel 408 FRAME base machined 54 334135B UHMW Piston Ceramic Metering Tube Assemblies NOTE The UHMW pisto
29. ion The process needs repeated for all three positions Phasing Shot Calibration Screen This screen is to instigate a phasing shot and to define the percentage of stroke for a phasing shot 64 Open Dispense Valve Position Calibration Screen This screen is to set or view the position with reference to the metering tube entrance where the dispense valve is opened during the forward stoke of the pump Dispense Amount Prohibit and View Cycle Counter Screen This screen will enable the user to lock out or enable the operator to change stroke percentage for the shot mode run screen The user will also be able to view the machine cycle counter Setup Screen Password Set Clear Screen lB2353 VLL H1 r 1234 b This screen will allow the user to view set or clear by entering four O s the password Setting a new password or clearing the password feature is identical to the method used to enter the setup screen if a non zero password is present 334135B Kits Kits Nylon and UHMW Piston Replacement Kits 653 653 651 Piston Sizes 080 119 653 Piston Sizes 160 960 651 Piston Sizes 120 159 When ordering a piston replacement kit the following puer et intelligent part numbering system applies for Nylon 651 jr PISTON 1 based pistons 652 SCREW 1 653 O RING 2 LCF Piston Size mm2 When ordering a UHMW replacement kit the following numbering
30. lso be adjusted for material viscosity Thicker materials should have the dispense valve open earlier and thinner materi als should have the dispense valve open later A positive value for Open Dispense Valve Timing indi cates the dispense valve will open after the piston is engaged in the cylinder A negative value indicates the dispense valve will open before the piston is engaged in the cylinder 32 If a high positive number is entered for ODV timing such as 6 0 mm the dispense valve may not open resulting in the fluid stalling against the dispense valve The fluid in the hose lines will remain under pressure until the piston is manually retracted using the Manual screen see Operator Mode Screen FiG 8 Open Dispense Valve Position Calibration 1 Navigate to the Open Dispense Valve Position Calibration Screen 2 Press the Dispense Valve Open Position Adjust but c ton S 3 Use the up and down arrows to enter a value for the ODV Timing 4 Press the Enter button Y to accept the new value or press the Abort Cancel button ez to keep the previous value 334135B Operation Startup 1 Locate the power switch at rear of machine and turn the power on The display module will automatically turn on and begin to load 2 Open the vented ball valve not provided 3 Ifthe machine is in Disabled Mode press the Power On button 5 to exit Disabled mode and to select a new operating mode
31. lve and air filter kit not provided with unit but available as kit 24R707 at the 1 4 NPT female air inlet NOTICE The system must have a bleed type ball valve that bleeds pressure downstream when closed Other wise the supplied air will need to be disconnected from the system whenever the pressure is relieved NOTE The system must use an air filter with a minimum flow rate of 30 scfm 9 Close the ball valve NOTE Air supply pressure must be between 80 psi 550 kPa 5 5 bar and 100 psi 690 kPa 6 9 bar Recom mended pressure is 100 psi 690 kPa 6 9 bar Ground System The equipment must be grounded to reduce the risk of static sparking Static sparking can cause fumes to ignite or explode Grounding provides an escape wire for the electric current 10 Follow Grounding instructions on page 23 334135B Installation Electrical Requirements 11 Connect AC power 100 240V 50 60 Hz sin gle phase to the power supply provided Connect the power supply to the machine as shown T NS Q K S CON 25 Setup Setup Before setting up the machine the user needs to be familiar with the LCM screens Refer to Appendix A LCM Icon Overview and Appendix B LCM Run Screen Overview starting on page 60 Perform Startup page 33 to access the LCM screens Piston Position Calibration e 1 953 15924 3821 KHAR AD Fic 4 Position Calibration Screen The position senso
32. n ceramic metering tube assemblies contain a carbide ball This ball replaces the standard check valve ball in pump assembly LCO1 12 If a UHMW piston ceramic metering tube assembly needs to be installed replace the original ball in pump assem bly LCO112 with the ball included with the pump pack age See Check Valve Rebuild Kit Installation on page 47 for installation instructions Reference Number and Description 1 Forcustom piston packages washer 603 part number will change by piston size as follows For piston sizes 80 100cc 15M089 For piston sizes 101 159cc For piston sizes 160 285cc For piston sizes 286 646cc For piston sizes 647 960cc 334135B Washer not used 15M099 15M100 15M101 601 602 603 604 605 606 607 Piston Tube UHMW Ring support Carbide Package pump Piston Washer piston Screw O ring Ball LC3160 LCG160 LCA160 LC3180 LCG180 LCA180 LC3200 LCG200 LCA200 LC3220 LCG220 LCA220 15M099 15K887 LC3240 LCG240 LCA240 LC3260 LCG260 LCA260 LC3280 LCG280 LCA280 LC3300 LCG300 LCA300 LC3320 LCG320 LCA320 LC3360 LCG360 LCA360 LC3400 LCG400 LCA400 120933 120874 116166 LC3440 LCG440 LCA440 63480 LCG480 LCA4g0 M100 e LC3520 LCG520 LCA520 LC3560 LCG560 LCA560 LC3600 LCG600 LCA600 LC3640 LCG640 LCA640 LC3720 LCG720 LCA720 LC3800 LCG800 LCA800 15M
33. n sequence Graphic used to indicate that the control has detected that one of the keys is stuck in the ON position Graphic used to indicate that the control has detected that readings from the linear position sensor are invalid Graphic used to indicate that the control has no or invalid readings for the extend retract and metering tube positions Graphic used to indicate the full retract position of the pump Graphic used to indicate the full extend position of the pump Graphic used to indicate the position on the pump where the piston first enters the pump metering tube 334135B Appendix A LCM Icon Overview Phasing Shot Graphic used to indicate the user wants to arm the machine to allow phasing shots when the user presses the dispense key or presses the optional machine footswitch input Phasing Shot Adjust Graphic used to indicate the user wants to adjust the position into the metering tube where the pump reverses during the phasing shot dispense Dispense Valve Open Graphic used to indicate the user wants to adjust the position with respect to Position Adjust the metering tube entrance where the valve is opened during the extend stroke of the pump of a dispense operation Allow Shot Amount Graphic used to indicate the user wants to allow shot amount adjustment from Adjust the main shot mode run screen Do Not Allow Shot Graphic used to indicate the user does not want to allow shot amount adjust Amount Adju
34. ng or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources Component Identification Component Identification Machine Fic 1 Machine Key N Control Cable A Power Switch B Aijr Inlet P Ground Wire and Clamp R Air Water Separator Assembly with Vented Ball Valve C System Air Pressure Relief Valve D Local Control Module LCM E Air Pressure Regulator F Drive Block G Air Motor Not Supplied 24R707 S Footswitch Connection T 24V Power Supply Machine Shield Screws M Machine Shield Dispense Head K Snuff Back Adjustment Knob H 24V Power Input J L 334135B Local Control Module LCM NOTICE To prevent damage to soft key buttons do not press the buttons with sharp object such as pens plastic cards or fingernails Component Identification Fic 2 LCM Key AA Dispense Request or Go key This key will dispense material and can not be disabled by the user as a setup screen option AB System Shut Down Key This key will disable the machine all outputs de energized and will place the machine in disable mode This key is always active AC Up and Down Navigation Arrow Keys Used to navigate between screens navigate within a screen used for numerical entry or used to select features AD Soft Key Inputs Function of the keys will reflect the graphic provided to the left of the respective key 334135B AE Status LED Solid System
35. ng 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com For patent information see www graco com patents TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 746 1334 Fax 330 966 3006 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 Original instructions This manual contains English MM 334135 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPO
36. ng out Chamfer pe 13 Apply pressure to the valve to snugly fit the assem LJ bled check valve into the check valve housing Fit the check valve seat 114 4 into the valve guide A NOTE Verify when the assembled check valve and U housing are turned up side down that the contents of the check valve stay in place AN The side of the seat with an outside diameter chamfer must point away from the ball 14 Use a wrench to insert the new valve and valve FiG 13 Check Valve Rebuild Kit housing into the pump end cap 15 Install the material male hose fitting into the check Prepare Machine for Kit Installation valve housing using a wrench 1 Relieve pressure See Pressure Relief Procedure 16 Before operating the machine activate a few shots page 33 to purge any air present in the material hose lines 2 To prevent machine movement press the Machine 17 Calibrate the machine if necessary Perform Setup page 26 Disable Mode key 2 3 Placea waste container below the dispense valve to catch any dispensed material 4 Push the drive block forward until pistons are fully extended 5 Move the waste container to below the check valve 6 Disconnect the male hose fitting from the check valve housing by loosening the hose from the hous ing See Pump Sub Assembly 248053 page 50 334135B 47 Parts Parts Fixed Ratio Base AN Torque to 140 in lb 15 8 Nem A Torque to 350 in lb 39 5 Nem A Torqu
37. nnect ground wire and clamp to a true earth ground Fluid hoses use only electrically conductive hoses Dispense Valve ground through a proper connection to a fluid hose and grounded pump Fluid supply container follow local codes Object being sprayed follow local codes Solvent pails used when flushing follow local code Use only conductive metal pails placed on a grounded surface Do not place the pail on a nonconductive sur face such as paper or cardboard which interrupts grounding continuity 334135B Installation Machine Installation Pump shaft polyethylene PE tank lid and PE tank lid gasket are coated with Krytox grease Wear protective gloves and cover exposed skin to avoid possible skin irritation on contact Read Krytox MSDS to know the specific hazards and follow manufacturer s warnings Locate Machine 1 Locate a bench top or open floor area to mechani cally mount the machine Ensure the location has access to compressed air and AC power and is well ventilated 2 Placethe machine on the designated location Allow the machine to rest on the rubber feet provided Mount Machine if Needed 3 Remove the shield locking screws on both sides then remove the protective shield 4 Attach the frame to the selected location by install ing fasteners not provided with unit through the two mounting holes See FIG 3 Fic 3 Mounting Holes 23 Installation Install Pump Tubes S
38. o the drive block 25 Tighten the lock nut Prepare for Operation 26 Fill tanks 27 Perform several shots to fill the pump with new material 28 Calibrate and phase the machine Perform Setup page 26 45 Repair Piston Cylinder Replacement Kit Installation NOTE See Piston Package on page 20 and Nylon and UHMW Piston Replacement Kits on page 65 for kit numbers AN The arrovv imprinted on the cylinder points toward the pump outlet Prepare Machine for Kit Installation 1 Drain the pump Empty the tanks Perform shots repeatedly until no material comes out of the dis pense valve 2 Relieve pressure See Pressure Relief Procedure page 33 3 Shut down the machine See Shutdown page 34 Disassemble Cylinder 4 Remove the four end cap screws 5 Remove the pump end caps Allow the cap to hang by the hose 6 Remove the cylinder and o rings from the pump housing 7 Push the drive block forward until pistons are fully extended 8 Usea wrench to prevent the pump shaft from rotat ing and remove the piston screw 46 9 Remove the piston and any front or rear washers from the pump shaft 10 Clean and inspect the washers Install Cylinder 11 Install the new piston and any front or rear washers 12 Install the piston screw NOTE Tighten the piston screw until the screw stops rotating then turn the screw an additional 1 8 turn 13 Fully retract the piston 14 Lubricate
39. oblem Cause Soo Machine dispensing off ratio One tank is empty Check tank levels Add material if necessary Tank ball valve closed Open tank ball valve Prime machine Machine out of phase Re phase machine Check valve malfunction Remove check valve clean or replace as necessary Piston worn or broken Replace piston Pumps drawing material back from Check valve stuck open Hemove check valve clean or valve hose replace as necessary 38 334135B Troubleshooting LCM Error Codes If an error condition exists the front Panel LED will blink the number of times corresponding to the error code number pause then repeat After the user acknowledges the generated error screen the error number will appear on the bot tom left hand side of the main run screen and the described blink sequence will continue If more than one error is present all will be presented separated by commas When the condition is cleared the corresponding error number will be removed from the main run screen If an error code is present the machine will not dispense Trigger Code Type Causes Condition Improper Machine has not been Perform pump position When Machine Cali calibrated or has been entries in Position Calibra requesting a bration calibrated incorrectly tion Screen Retract posi dispense tion must be less than operation metering tube position which should be less than the fully extend position Bad Linear 1 Connection to posi
40. on mounting valve HMI mounting HMI BASE arm mounting 3 3 802 i6P409 BlOCK mounting onm 2 f r 808 i6P550 BLOCK mounting rear 2 p ro a NENNEN 806 Iskes AM mounting HM S09 121046 TUBE VAxTAtwm polyurethane 6 6o 810 94070596 FITTNG ebow swivel gt 2 811 126800 PLUG round finishing 2 2 NENNEN 44 i013 SCREWsokehea 2 Not shown 14 334135B Air Filter and Ball Valve 24R707 Ref 701 702 703 704 705 Part 157350 106148 155665 Description VALVE vented 2 way ADAPTER FILTER air 3 8 NPT UNION adapter NIPPLE pipe Quantity 1 1 1 1 1 High Temperature Grease 115982 Footswitch 255244 334135B Hecommended Parts Hecommended Parts Tanks 1 1 2 in NPT Flanges 24W417 8 Liter Twin Polyethylene Tanks and Lids 24W415 8 Liter Twin Polyethylene Tanks and Lids with Shut Off Valves 24W416 1014 16 334135B Hecommended Parts Quantity Description pie ees ees 95 0223 00 O RING O RING HOS veg SCREW sarin 2 2 1004 720904 SCREW Moxiamm Je 3 120908 pm 1006 120908 NUTRexlckMBxi25 2 2 007 120907 WASHER peno 4 2 1008 120908 WASHER plan M Ja 4 1009 BREATHER 1010 T2011 CLAMP gaptespinchhose 2 2 jo KOLN SCREW 255280 VALVE ball mos eo
41. ot switched and that the linear position sensor is properly installed 7 Press the Enter button K to accept the value or press the Abort Cancel button za to keep the previous value Extended Piston Position 8 With air pressure applied to the machine high light the Extend Piston button 9 Press the Dispense Request button ton will fully extend and a number 3600 3900 should be displayed If a number outside of this range is displayed ensure the air cylinder air line connec tions are not switched and that the linear position sensor is installed correctly NOTE If the piston does not extend after pressing the Dispense Request button the air pressure may need to be increased Use system air pressure regulator to increase the air pressure in increments of 10 psi until the piston activates Material will be dispensed when adequate pressure is achieved 334135B 10 Press the Enter button Eam to accept the new value or press the Abort Cancel button faze to keep the previous value Engaged Piston Position 11 Close the vented ball valve to eliminate the air pres sure to the system 12 High light the metering tube entrance position but I ton ra 13 With no air pressure in the system press the Dis pense Request button 1 14 Move the piston drive block until it just begins to engage the cylinder using one of the following meth ods No material should be dispensed
42. pense quantity It is most efficient to adjust the snuff back while material is dispensing but it can also be adjusted when there is no air pressure in the system 1 Navigate to the Shot Mode Screen or Operator Mode Screen 2 Select a small size shot 3 Ifa static mixer is not in place install one then prime the machine See Prime the Dispense Head page 28 4 Place a waste container under static mixer a j l J ls z 5 Press the Dispense Request button ED 6 Inspect the tip of the static mixer for dripping mate rial or for air bubbles traveling up the mixer 7 Perform another shot and while dispensing adjust the snuff back adjustment knob as follows e If an air bubble is moving up the mixer turn the knob clockwise to decrease snuff back e f material is hanging from the tip of the mixer turn the knob counterclockwise to increase snuff back 8 Repeat step 7 until snuff back is adjusted as desired 334135B Setup 31 Setup Adjust Open Dispense Valve ODV Timing When a shot is performed the dispense valve needs to open at a precise time for material to be dispensed properly If the dispense valve opens too early material may drain from the static mixer before the shot starts If the dispense valve opens too late pressure may build in the machine before the dispense valve opens causing material to forcefully spray out of the mixer The Open Dispense Valve Timing should a
43. r assigns a numeric value to the loca tion of the piston Higher numbers indicate the piston is extended and lower numbers indicate the piston is retracted The Piston Position Calibration procedure teaches the machine the location of the most extended piston posi tion H the most retracted piston position i and the position where the piston engages the pump d cylinder 7x Perform the Piston Position Calibration procedure when first setting up the machine Also perform this pro cedure if the linear position sensor piston or any elec tronic component has been replaced Press the Setup Screen button to enter the setup screens Prepare Machine for Calibration 1 Ensure that both piston shafts are screwed all the way into the drive block 2 Navigate to the Position Calibration Screen 26 3 Place a waste container under the dispense valve to capture any dispensed material 4 Ensure the system air pressure is on by opening the vented ball valve and the system air pressure regu lator shows air pressure in the system Retracted Piston Position 5 With air pressure applied to the machine high light 7 the Retract Piston button 6 Press the Dispense Request button p The pis ton will fully retract and a number from 1250 to 1600 will be displayed next to the Retract Piston button If a number outside of this range is displayed ensure the air cylinder air line connections are n
44. r piston sizes 286 646cc For piston sizes 647 960cc 334135B Washer not used 15M099 15M100 15M101 21 Pump Tube Combination Information Pump Tube Combination Information Pump Tube Combination Information Power Factor Ratio Large Piston Small Piston Minimum Maximum 3 in 4 5 X 1 mm mm Shot Size cc Shot Size cc Air Motor in Air Motor 1 960 960 12 4 71 0 2 5 1 640 640 8 3 47 3 4 8 1 480 480 6 2 35 5 5 11 1 320 320 4 1 23 7 7 16 1 240 240 3 1 17 7 10 21 1 160 160 2 1 11 8 14 x 1 120 120 1 6 8 9 19 x 1 80 80 1 0 5 9 29 x 2 960 480 9 3 53 2 3 7 2 640 320 6 2 35 5 5 11 2 480 240 4 7 26 6 6 14 2 320 160 3 1 17 7 10 21 2 240 120 2 3 13 3 13 29 2 160 80 1 6 8 9 19 x 4 960 240 7 8 44 3 4 9 4 640 160 5 2 29 6 6 13 4 480 120 3 9 22 2 8 17 4 320 80 2 6 14 8 11 26 6 960 160 7 3 41 4 4 9 6 480 80 6 20 7 8 18 x Pump tube combination is not recommended 22 334135B Installation Grounding The equipment must be grounded to reduce the risk of static sparking and electric shock Electric or static sparking can cause fumes to ignite or explode Improper grounding can cause electric shock Grounding provides an escape wire for the electric current General Grounding Guidelines Pump use ground wire and clamp P Refer to page 6 for component identification Co
45. rated if an error condition becomes active The screen will contain the code for the condition a graphic describing the condition the standard Graco alarm bell and a soft key prompting the user to acknowledge the condition Once the condition has been acknowledged by the user the screen will return to the main run screen If the condition is still present after acknowledgement the code previously presented to the user will be displayed on the bottom left hand corner of the main run screen Once the condition is corrected the code displayed will be removed 63 Appendix C LCM Setup Screen Overview Appendix C LCM Setup Screen Overview x Password Entry Screen If a password is programmed into the LCM the user will be prompted to enter a password If no password has been entered all O s on the password set clear setup screen this screen will be bypassed Position Calibration Screen 1 953 1924 3821 KARA x i P This screens is used to set or observe the proper posi tions on the linear position sensor for full extend retract and entrance into the metering tube All valid entries must be present for the machine to operate The extend position must be greater than the metering tube posi tion which must be greater than the retract position When the position is accepted the real time position sensor reading in the middle of the screen will be trans ferred to above the graphic for the corresponding posi t
46. s 5 Use a4 mm hex key to tighten screws holding dis pense head in place if applicable 6 Route the fluid hoses connected to the dispense head so they are always below the dispense head This ensures any air in the hoses will travel to the dispense head 7 Navigate to the Shot Mode Screen or Operator Mode Screen 8 Ensure there is a sufficient amount of material in the tanks 28 334135B Phasing Adjustment FiG 6 Phasing Calibration Screen When the machine executes a shot materials from Tank A and Tank B enter the static mixer where they are mixed and then dispensed In order for the materials to mix at the desired ratio both materials must enter the static mixer at the same time The timing of the materials entering the static mixer is dependent on the adjustment of the phase adjustment screw for each piston Prepare the Machine 1 Placea waste container under the dispense valve to catch dispensed material 2 Remove the static mixer from the dispense valve 3 Install the ratio check nozzle onto the dispense valve ti12392a D T Fic 7 Ratio Check Nozzle 4 f necessary place a stand under the ratio check nozzle to support the waste container close to the nozzle 5 Navigate to the Phasing Shot Calibration Screen 334135B Setup Adjust Dispense Quantity rr 6 Press the Phasing shot button 5 a to enter phasing mode 7 Press the Dispense Request button footswitc
47. s SCREWMeGEmm o 6 o RING Took 09 FITTING ange 15K840 O RING 1023 j TANK 8 iter 1024 15M226 BALLAST 15K842 BALLAST 1025 120915 CAP PLUG square 1026 15M237 FLANGE 1 1 2 in NPT pom Not Shown n n 334135B 17 Hecommended Parts Hose Packages Unheated Non Recirculating Hose 1402 ti12446a Pd 1401 1404 1403 8 CA we Assembly LC0801 Shown AN Apply thread sealant tape to male npt threads before assembly Reference Number and Description 1401 1402 1403 1104 Hose Package Description Hose Assembly 90 Deg Elbow Adapter Bushing LCO801 3 16 in x 30 in 16C501 94 0144 S 25 94 1000 98 94 0488 98 L C0802 3 16 in x 120 in 16C506 94 0144 S 25 94 1000 98 94 0488 98 L C0803 3 16 in x 180 in 16C507 94 0144 S 25 94 1000 98 94 0488 98 L C0804 1 4 in x 30 in 16C510 94 0148 S 25 J6900040 vm LCO8O5 1 4 in x 120 in 16C515 94 0148 S 25 J6900040 al LCO806 1 4 in x 180 in 16C516 94 0148 S 25 J6900040 Ps L C0807 3 8 in x 30 in 16C519 94 0149 S 25 94 1007 98 a LCO808 3 8 in x 120 in 16C524 94 0149 S 25 94 1007 98 Se LCO809 3 8 in x 180 in 16C525 94 0149 S 25 94 1007 98 es LC0400 3 8 in x 30 in 16D261 94 0149 S 25 94 1007 98 sO LCO401 3 8 in x 120 in 16D266 94 0149 S 25 94 1007 98 NENNEN LC0402 3 8 in x 180 in 16D267 94 0149 S 25 94 1007 98 ee LC0810 1 2 in x 30 in 16C529 94 0150 S 25
48. ssing the mode select designation soft key option from any of the three possible run mode screens When activated the user can select between Shot Manual and Maintenance modes The highlighted graphics in the top left portion of the display will indicate the current selection 334135B Maintenance Mode Run Screen Used for machine testing The user will be able to extend or retract the pump or open and close the dis pense valve from this screen Once the user has navi gated to function to be implemented the user simply needs to press the dispense request key to issue the request Shot Amount or Stroke Adjust Screen If in shot mode and the user has enabled this run screen adjustment via a setup screen option the user can adjust the shot amount by simply pressing the Up or Down arrow keys then pressing the accept user entry softkey The minimum percent required is 15 percent Run Screen while Dispensing Additional information is provided during a dispense operation consisting of a progress bar representing the current 96 complete of the dispense operation shot mode only and the amount of time elapsed for a dis pense During a dispense the run screen programming options are no longer available Once the dispense is completed the screen will return to the main home run Screen 334135B Appendix B LCM Run Screen Overview Error Code Acknowledgement Screen amp E3 A OK This screen will be gene
49. st ment from the main shot mode run screen 334135B 61 Appendix B LCM Run Screen Overview Appendix B LCM Run Screen Overview Splash Screen GRACO A This screen is activated during a boot up condition The splash screen will only be present approximately for five seconds Disable Mode Screen E When the system is in this mode all outputs are dis abled This mode is activated in the bootup situation or if the user presses the System Shut Down Key To exit this mode the user simply needs to press the Power On icon softkey Shot Mode Screen This mode is the dispensing mode where the user can define a shot amount by defining the percentage of stroke for the dispense operation When dispensing in this mode the machine will produce the same amount of material for each dispense To dispense out of this mode the user needs to momentarily press the dis pense key or press an optional footswitch 62 Operator Mode Screen This mode is the dispensing mode where the dispense amount is dictated by the duration the user is requesting the dispense To dispense in this mode the user can either press and hold the dispense key or press and hold an optional footswitch If the user releases the footswitch or dispense key the dispense operation will terminate and the pump will return to the retract position unconditionally Mode Selection Programming Screen This programming mode is entered by pre
50. sure or temperature rating of the lowest rated system com ponent See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it Use equipment only for its intended purpose Call your distributor for information Houte hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking movi
51. tainer at the end of the dispense head and press the Dispense Request button J or the footswitch NOTICE 11 Repeat the previous step until no air comes out of If the dispense head is not primed chemical cross the dispense valve over may occur resulting in cured material in the dis pense head hoses and or pumps 12 If phasing adjustments and ratio checking are not required use the following procedure to attach the static mixer 1 Remove static mixer from the dispense head if installed a Attach the static mixer with the dispense head pointed up 2 Turn snuff back adjustment knob fully clockwise This will prevent the dispense valve from closing b s Hold waste container at end of dispense head between priming shots and press the Dispense Request button 3 Usea4 mm hex key to loosen the screws holding the dispense head in place or the footswitch c Repeat the previous steps until static mixer has been purged of air 13 Use a 4 mm hex key to loosen screws holding dis pense head in place 14 Rotate dispense head back to normal dispensing position 15 Use a 4 mm hex key to tighten the screws holding the dispense head in place AS ti12391a Fic 5 Prime Dispense Head 16 Adjust snuff back to proper setting for operation n See Adjust Dispense Valve Snuff Back on page 31 4 Rotate or remove the dispense head so the tip is above the fluid input hose
52. the last mode used Shot or manual and display the corresponding Shot Mode Designa tion Operator Mode Des ignation Maintenance Mode Designation Mode Select Desig nation Setup Screen Desig nation Next Field Designa tion Accept User Entry Abort User Entry Stuck Key Bad Linear Sensor Improper Machine Calibration Retract Position Extend Position Metering Tube Entrance Position Aut mtee o0 60 mode on the home run screen Used on main home screen to indicate the machine is in shot mode On the maintenance mode screen it also indicates the user wants to either close or open the machine dispense valve Used on main home screen to indicate the machine is in Manual mode Used on main home screen to indicate the machine is in Maintenance mode When the corresponding soft key is pressed the machine will enter a mode select run screen When the corresponding soft key is pressed the machine will enter the start of the setup screens for the machine When the corresponding soft key is pressed the user will navigate into a screen or to the next field within a screen When the corresponding soft key is pressed the user accepts the value s or options shown on the screen When the corresponding soft key is pressed the user aborts the value s or options shown on the screen Activating this option will essentially allow the user to go back one step in the programming or screen navigatio
53. the new o rings with high temperature grease part 115982 15 Insert the lubricated o rings into the grooves of the pump housing and end caps 16 Install the cylinder between the pump housing and end cap See note in illustration 17 Secure cylinder in place with the four end cap Screws Prepare Machine for Operation 18 Fill tanks 19 Perform several shots to fill the pump housing with new material 20 Calibrate and phase the machine See the operation manual referenced at the beginning of this manual for procedure 334135B Repair Check Valve Rebuild Kit 7 Remove the check valve housing from the pump Installation endcap by loosening the housing with a wrench 8 Remove the existing check valve from the housing by inserting a screwdriver or dowel rod into the female threaded end of the check valve housing 9 Place the new check valve ball guide 114 3 ona NOTE See Pump Sub Assembly 245053 page 50 for bench with the open end up Install the check valve pump sub assembly part references spring 114 2 into the guide 10 Install the check valve ball 114 1 on top of the spring 114 2 11 Place the seat 114 4 on top of the check valve ball 114 1 with the outside chamfered side of the seat facing away from the check valve ball 12 Hold both ends of the assembled check valve assembly and install the check valve into the unthreaded end of the check valve housing with the 114 3 ball end faci
54. 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
55. tion 1 Verify connections to the Invalid read Position Sen sensor disconnected sensor ings from the sor sensor 2 Power to position sen 2 Verify proper readings from em Aa sor interrupted sensor on setup screen 1 3 Bad position sensor 3 Replace sensor Stuck key Alarm 1 Key is in an active Replace LCM Module If key is state detected to LL be active for 2 Tactile switch on LCM more than 30 is shorted or broke seconds 334135B 39 Repair Repair HydraCheck Kit Installation 24W336 n A Be sure that system pressure is relieved and disabled before proceeding FiG 11 HydraCheck Installation Fixed Ratio Base NOTE The HydraCheck kit is intended to be used with Install HydraCheck Shock low viscosity materials to minimize splashing It is not intended to be used as a timer or flow control device 6 Install the shock absorber through the opening in the pump sub assembly with the groove for the snap ring on the back of the pump assembly The shock pars NGRIN sa absorber can be inserted through the front 1 Navigate to the Maintenance screen 7 Install the shock snap ring included with shock not iJ shown onto the shock absorber in the groove far 2 Press the Retract Piston button thest from the pump sub assembly 3 Relieve system pressure See Pressure Relief Pro 8 Install set screw and torque to 85 in lb 9 6 Nem cedure page 33 4 Loosen the machine shield screws 5 Remo
56. valve Refer to MD2 Valve Instructions manual for part information 34 334135B Maintenance Maintenance Schedule Check Water Air Separator Daily before use 1 Check water air separator for water Not provided 2 Open valve at base of water air separator to purge water Check Desiccant Dryer only Daily before use 1 Check the color of the desiccant installed if chemical is moisture 2 Replace as required sensitive Check Tanks Daily before use 1 Check material levels and refill as necessary 2 Verify the material reservoirs are vented properly Check Dispensing Ratio Daily before use oras See Phasing Adjustment page 29 required Clean Pump Shafts Daily after shutdown See Clean the Pump Shafts on this page Clean Dispense Head See Shutdown on page 34 Disassemble and Clean Dispense As required See Disassemble and Clean the Dispense Head on Head this page Upgrade LCM See Install Upgrade Token on page 36 Clean the Pump Shafts Disassemble and Clean the 1 Close the vented ball valve at the left rear of the Dispense Head machine 1 Relieve pressure See Pressure Relief Procedure page 33 2 Press the Machine Disable Mode key f 3 Push the piston block to the fully retracted position 3 2 Remove the dispense head from machine Dismantle the dispense head See MD2 Dispense Valve manual referenced at the beginning of this 4 Clean both pump shafts with a compatible solvent manual and lubri
57. ve the machine shield 40 334135B Install Adjustment Screw Cap 9 Loosely install hex nut and adjustment cap onto the air cylinder shaft Adjust the Adjustment Screw Cap 10 Push the drive block forward until resistance is felt when it engages the cylinder Make sure the resis tance is not due to shock absorber contact with the adjustment screw or adjustment cap 11 Adjust the adjustment screw or adjustment cap until it contacts the shock absorber 12 Hold the adjustment cap in place and tighten the hex nut against the adjustment cap Prepare Machine for Operation 13 Open the ball valve to pressurized the system Adjust Shock Resistance 14 Execute a shot to see how the shock absorber affects the speed of the drive block 15 The shock absorber has a numeric scale on one side Rotate the knob with the scale to a higher value for more resistance Rotate the knob to a lower value for less resistance 16 Repeat these steps until the desired resistance is achieved 334135B Repair 41 Repair Air Cylinder Rebuild Instructions AN Finger tighten all 4 bolts prior to vvrench tightening For vvrench tightening turn each bolt 1 4 turn in a cross pattern until all 4 bolts are torqued to 350 in Ib 40 Nem A Torque to 1200 in Ib 136 Nem A Coat all sliding surfaces with lubricant part 115982 AN Apply sealant tape to npt fittings Prepare Machine for Kit Installation Disassemble the Air Cylinder
58. wrenches to break loose the locking nut 002 from the phase adjust ment screw 003 on the A material side b Hold the phase adjustment screw 003 sta tionary with a 13 mm wrench C Usea 7 mm wrench to turn the piston shaft 001 counterclockwise 1 4 turn or less to move the A piston forward NOTE It is highly recommended that all of the phasing adjustment be done to one side or the other not both NOTE Ensure the piston shaft and phase adjustment screw do not rotate while tightening the locking nut 002 in the following step 11 Hold piston shaft 001 and phase adjustment screw 003 in place with a 7 mm and 13 mm wrench and tighten locking nut 002 against phase adjustment screw with a 13 mm wrench Watch the dispense valve carefully to observe which material is dispensed first Press the Dispense Hequest button j or the foot switch to dispense material If one material exits the dispense nozzle before the other go back to step 10 Exit Calibration Mode 13 Navigate to the Shot Mode Screen or Operator Mode Screen 334135B Adjust Dispense Valve Snuff Back At the end of a shot a small amount of material is drawn back into the static mixer to prevent extra material from being dispensed If too much snuff back occurs air will enter the static mixer and can travel up into the dispense valve If too little snuff back occurs the materials may drip out of the static mixer and affect dis
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