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Graco 309790ZAA User's Manual

1. 309790ZAA 24 35 36 38 677 68 Parts 15 16 14 KU 7 1924 34 n a7 gg 75 Parts MD2 20 ft Automatic See Graco Manual 312185 Wide Ratio Module No 24H258 Close Ratio Module No 24H259 Ref No 76 Part No 255182 255180 15K688 LC0079 157350 122969 H52525 503536 207946 552026 16G003 Description Qty VALVE MD2 1 1 hard seats 1 24H258 VALVE MD2 10 1 hard 24H259 1 NUT retainer ratio check 2 MIXER static 3 8 x 24 50 ADAPTER 3 8 npt x 1 4 npt 1 FITTING elbow 1 4 npt x SAE 06 2 9 16 18 thread HOSE fluid nylon 1 2 in 13 mm 1 ID 3 8 npsm fbe 25 ft 7 6 m long FITTING nipple reducing mod SWIVEL straight HOSE PTFE sst 10 hp 20 ft FITTING adapter ND Part No 617467 160327 189018 598140 514607 552071 156971 947937 155570 C19008 Description Qty BUSHING hex reducing 3 4 x 12 UNION adapter 90 SWIVEL 5800 psi FITTING elbow 5 32T x 1 8 in npt m TUBE nylon 2 5m
2. A System Air Shutoff Valve bleed type L Component A and Component B Feed Pump Air B Main Air Filter Motor Lubricator C Component B Ram Directional Valve M Component B Ram Plate with Vent Stick or Valve D Component B Ram Air Pressure Regulator N Component A Ram Plate with Drum Vent Valve E Component B Air Supply Valve bleed type O Component A Pump Air Regulator F Component B Air Supply Regulator P Component A Ram Directional Valve G Component A Air Supply Valve Q MD2 Gun with Disposable Mixers H Component B Outlet Pressure Gauge R Component A Ram Air Pressure Regulator J Component B Feed Pressure Gauge S Accessory Gun Air Supply Valve K Component A Feed Pressure Gauge ED ad G bus La E UN B J R 1 D P C 7 J ti16735a FIG 1 10 309790ZAA v Component B behind Supply Header H pos Component B Fluid Regulator IL T Installation Supply header system supplied by others not covered in this manual Component A Supply Header Component A Fluid Regulator B L ti16759a FIG 2 Key Fia 3 Q 2K Gun X Air Trigger Pilot V Disposable Mixer Element Y Component B
3. Tank air shutoff valve Gently roll an unopened pail of component B on the floor for several revolutions to mix it Open the pail outlet and carefully pour the material into the tank through a funnel Close the drain cock fitting and screw on the cap Make sure the silica gel in the desiccant filter is blue If the gel is pink replace it part no 106498 or bake out the moisture The desiccant filter is an air dryer for moisture sensitive materials it is not included with the pack age 8 Pressurize the tank with dried air by opening the component B air shutoff valve and the pressure tank air shutoff valve E Dry Air Line a Desiccant filter is TE 7 e fo QUE HA BE EE Y o o 5 Q 5 Hi FIG 28 15 1 Component B pump de gt a Sn ti3259ax 32 309790ZAA Adjust Ratio on Variable Ratio Machine The ratio of this unit is determined partially by the differ ence in the area of the metering cylinders and partially by the position of the adjustable fulcrum point in the Uni bar linkage assembly With the fulcrum in the center next to stop at left of center each meter cylind
4. Fic 12 J a a Plate TI3260B 309790ZAA Pressure Tank with 15 1 Booster 1 Relieve tank pressure before opening 2 Remove the pressure tank lid and any items shipped inside the tank Make sure the tank is clean or use the liner supplied 3 Be sure the desiccant air dryer is mounted in the component B tank air supply of the proportioner air control module See FIG 28 page 32 4 Gently roll an unopened pail of component B on the floor for several revolutions to mix it 5 Open the pail outlet and carefully pour component B into the tank 6 Immediately close the tank by tightening the T handles GG evenly Fic 13 FiG 13 From component B pump air Booster Pump regulator on proportioner module bu A o o RE H m Ipi Uu F 1 o o To component B inlet on proportioner HB o M o LU m Setup Pressurize the tank with dried air by opening the component B air shutoff valve S and the pressure tank air shuto
5. TT TI ERN f 0717E 63 309790ZAA Parts 34 1 Senator on 55 Gallon Ram See Graco Manual 308027 Module No 965572 64 Part No 235497 160327 215238 214651 109126 222769 241253 276025 102637 113269 Description VALVE check UNION adapter 90 HOSE coupled 61220 HOSE coupled 61209 17 ft HOSE coupled 10 ft PUMP Senator 4 5 cm RAM pneumatic EPDM 55 gallon CLAMP SCREW cap VALVE ball vented 500 9 ND Ref No 20 21 22 23 25 30 31 34 35 36 Part No 109495 111803 100133 158979 114363 158256 100896 206537 155541 158212 9 lt lt Description PACKING o ring SCREW cap hex head WASHER lock FITTING nipple pipe reducing VALVE ball SWIVEL union assembly FITTING bushing pipe CLAMP drum UNION swivel BUSHING 309790ZAA 31 1 Bulldog on 55 Gallon Ram Module No Ref No Part No 237261 235497 160327 215238 214651 109126 158212 158555 241253 J O O1 B ND NO 309790ZAA 570141 Description PUMP Bulldog 31 1 VALVE check UNION adapter 90 HOSE coupled 61220 HOSE coupled 61209 17 ft HOSE coupled 10 ft BUSHING NIPPLE reducing RAM pneumatic EPDM 55 gallon Qty
6. 24 309790ZAA MD2 Disposable Mixer Gun Models Follow steps 10 12 10 Fit the hose to the gun Trigger the gun into a waste container 11 Open the component B feed air shutoff valve E FIG 15 Component B will feed through the metering cylinder to the mix gun 12 When bubble free material is dispensed stop trig gering the gun All Models The system is now ready to dispense mixed material CAUTION The materials will cure after mixing Purge the mixer hose and gun with clean material before the material begins to cure 309790ZAA Setup 25 Setup 26 309790ZAA Operation Operation Pressure Relief Procedure 3 If a component B pressure tank is used open its vent refer to page 23 WARNING 4 Hold a metal part of the gun firmly to the side of a grounded metal pail and trigger the gun to relieve N pressure Read warnings page 4 and follow the Pressure 5 For both component A and component B open the Relief Procedure whenever you respective pump bleed valves having a waste con e are instructed to relieve pressure tainer ready to catch the drainage FIG 19 e stop dispensing check or service any of the equipment e install or clean the nozzle 1 Purge mixed material if necessary See page 29 2 Close the main air shutoff valve A FIG 18 Bleed Valve FIG 19 6
7. Scale Setting 5 63 7 13 8 13 8 85 9 38 9 80 10 13 Minor Stroke 3 00 2 00 1 50 1 20 1 00 0 86 0 75 309790ZAA 15 Setup 8900 Proportioner 2 1 8 1 Variable Ratio Setting in Inches from Pivot or Minor Stroke Mix Ratio by Volume Scale Setting Minor Stroke 2 5 63 3 00 3 7 13 2 00 4 8 13 1 50 5 8 85 1 20 6 9 38 1 00 7 9 80 0 86 8 10 13 0 75 12 Mix Ratio by Volume Scale Setting 5 63 7 13 8 13 8 85 9 38 9 80 10 13 Minor Stroke 3 00 2 00 1 50 1 20 1 00 0 86 0 75 76 309790ZAA 8900 Proportioner 5 1 20 1 Variable Ratio Mix Ratio by Volume Scale Setting Minor Stroke 5 5 63 3 00 7 7 13 2 00 10 8 13 1 50 12 8 85 1 20 15 9 38 1 00 17 9 80 0 86 20 10 13 0 75 Setting in Inches from Pivot or Minor Stroke Setup 0 Mix Ratio by Volume 5 7 10 12 15 17 20 Scale Setting 5 63 7 13 8 13 8 85 9 38 9 80 10 13 Minor Stroke 3 00 2 00 1 50 1 20 1 00 0 86 0 75 309790ZAA 17 Setup Before You Load Material 1 Check fluid and air lines and tighten if necessary 2 Make sure there is a minimum overhead clearance of 110 in 279 cm for 55 gallon supply 3 Fill air line lubricator for the 8900 Proportioner mod ule with SAE 10 W non detergent oil not included 4 Fill the
8. k Fire and Explosion Hazard Improper grounding poor ventilation open flames or sparks can cause a hazardous condition and result in fire or explosion and serious injury e Ground the equipment and object being sprayed See Grounding page 12 e Ifyou experience static sparking or electric shock stop operation immediately Identify and correct the problem e Provide fresh air ventilation to avoid building up flammable fumes e Keep the spray area free of debris including solvent rags and gasoline e Extinguish all sources of flames in the spray area including pilot lights and cigarettes e Donot turn on or off any light switch or plug or unplug electrical equipment in the spray area while operating or if fumes are present e Do not operate a gasoline engine in the spray area e Keep a fire extinguisher in the work area m p 309790ZAA Moving Parts Hazard Moving parts such as priming piston and wiper plate can pinch or amputate fingers Keep clear of mov ing parts when starting or operating equipment and when equipment is pressurized Keep hands and fingers away from the priming piston e Keep hands away from the ram wiper plate and pail lip e Before servicing follow the Pressure Relief Procedure page 27 to avoid equipment startup Theory of Operation Theory of Operation Use The 8900 Proportioner is used with two component materials where one or both components is high viscos
9. FITTING tube VALVE control NUT cap TUBE nylon 3 7 ft REGULATOR air 1 4 in npt 9 lt y Nm mm mm mm RER Ref No 35 36 37 38 39 40 45 47 50 52 53 55 56 57 58 59 60 Part No 110319 104765 155541 238925 166533 110225 237569 180916 114003 114320 160327 115901 235497 157191 215238 214656 109126 156684 Description GAUGE pressure air 1 8 in npt PLUG pipe headless UNION swivel 90 PISTON ram 5 gal SUPPORT pump VALVE ball vented WIRE assy 25 in MANIFOLD adapter VALVE safety FITTING connector 1 8 npt f UNION adapter 90 TRIM edge protection VALVE check FITTING bushing pipe HOSE coupled 61220 HOSE coupled 61209 10 in HOSE coupled 10 in UNION adapter swivel Qty OO 309790ZAA Parts 59 309790ZAA Parts 23 1 Monark on 5 Gallon Ram See Graco Manuals 308026 and 306838 Module No 570142 Ref Ref No Part No Description Qty No Part No Description Qty 1 184147 SHIELD 5 gallon ram not shown 1 50 110318 REGULATOR air 1 4 in npt 1 2 206994 FLUID TSL 8 oz bottle not shown 1 51 104765 PLUG pipe headless 1 4 222782 PUMP Monark 1 52 113896 VALVE control 1 11 222812 PLATE wiper 5 gallon 1 53 166552 CAP cylinder 1 19 156823 UNION swivel 1 54 206726 BASE and cylinder 1 25 155470 UNION
10. In the center position the dispense ratio is the same as the meter cylinder ratio The linkage is adjustable depending on the location of the fulcrum point The linkage must be adjusted for each material application so the combined linkage and meter cylinder ratio equals the desired material mix ratio by volume The ratio may be checked by weight but the machine meters by volume and that ratio must be known before proceeding The initial linkage adjustment point can be calculated by inserting known values into the formula on page 35 The result is the distance in inches from the center of the ful crum point to the center of the component B meter cylin der For convenience measure the distance between the grease fitting on the top of the fulcrum and the cen ter of the component B cylinder meter rod 14 FIG 6 Set Scale Refer to the 8900 Proportioner Output Charts on the fol lowing pages to set the scale Make final adjustments after the material is loaded See instructions on page 33 for detailed ratio check instructions 309790ZAA Output Charts Ratio Settings 8900 Proportioner 1 1 4 1 Variable Ratio Mix Ratio by Volume Scale Setting Minor Stroke 1 5 63 3 00 1 5 7 13 2 00 2 8 13 1 50 2 5 8 85 1 20 3 9 38 1 00 3 5 9 80 0 86 4 10 13 0 75 Setting in Inches from Pivot or Minor Stroke Setup Mix Ratio by Verne 1 1 5 2 2 5 3 3 5 4
11. 156877 100175 511351 108233 156823 965766 101353 157416 158491 501459 110460 598140 510220 104165 164815 503279 112013 112014 112015 112020 112021 112022 Description FITTING pipe hex FITTING elbow male ACTUATOR air 1 8 npt f MIXER static 1 2 npt COUPLING hex MIXER tri core 1 2 m x 1 2 f UNION swivel ADAPTER luer lock 1 4 in npt NOZZLE needle NOZZLE needle HOSE coupled 61120 1 ft ADAPTER FITTING nipple reducing FITTING nipple pipe reducing VALVE ball 3 way BUSHING pipe MIXER pipe sst 1 4 4 2 in 12 el MANIFOLD ratio check 8900 shot VALVE ball NIPPLE long COUPLING pipe MIXER static VALVE needle UNION swivel VALVE 1k ul machine mount NIPPLE pipe UNION swivel 90 FITTING nipple VALVE toggle air FITTING el male swivel 10 32x5 32 FITTING elbow 5 32t x 1 8 in npt m VALVE air 4 way spring 1 4 npt FITTING tube FITTING adapter tee FITTING union straight 1 8 in mxf SW NOZZLE needle NOZZLE needle NOZZLE needle NOZZLE needle NOZZLE needle NOZZLE needle 9 lt ss oa PON NWI ND NN D NNO AT lt a Na D D ND D ND 309790ZAA 9 832 13 7 91 12 1745 15 16 10 11 88
12. 4 4 1 Fixed 1000 250 570374 5 5 1 Fixed 500 100 570375 6 10 1 Fixed 1000 100 570376 7 9 1 Fixed 1000 111 246557 A 1 1 to 4 1 Variable 500 500 570377 B 2 1 to 8 1 Variable 500 250 570378 D 5 1 to 20 1 Variable 500 100 570380 Code B Pump Feed Module Selection for Component A Module Number A 20 1 President on 5 Gallon Ram 965571 B 34 1 Senator on 5 Gallon Ram 965597 C 23 1 Monark on 5 Gallon Ram 570142 D 20 1 President on 55 Gallon Ram 570114 E 34 1 Senator on 55 Gallon Ram 965572 F 31 1 Bulldog on 55 Gallon Ram 570141 G 20 1 Senator on 55 Gallon Drum 570309 H 9 1 DynaMite 1 Gallon Can Ram 570249 J 10 Gallon Press Tank with 15 1 Booster 570037 K 10 1 President 5 Gallon Pail Cover 570264 N None Code C Pump Feed Module Selection for Component B Module Number A 20 1 President on 5 Gallon Ram 965571 B 34 1 Senator on 5 Gallon Ram 965597 C 23 1 Monark on 5 Gallon Ram 570142 D 20 1 President on 55 Gallon Ram 570114 E 34 1 Senator on 55 Gallon Ram 965572 F 31 1 Bulldog on 55 Gallon Ram 570141 G 20 1 Senator on 55 Gallon Drum 570309 H 9 1 DynaMite 1 Gallon Can Ram 570249 J 10 Gallon Press Tank with 15 1 Booster 570037 K 10 1 President 5 Gallon Pail Cover 570264 N None 309790ZAA Models Code D Mix Kit Selection Module Number 1 Cart Fill Medium Viscosity Wide Ratio 570248 2 Cart Fill High Viscosity Wide Ratio 570318 3 Brush Grade High Viscosity Wide Ratio 570358
13. 52 Limit Valve os izseiibeiR RES 53 Air Control esse sainte st Dict 54 4 Way Valve 55 Pump Feed Module Selection for Component A or Component B 56 20 1 President on 5 Gallon Ram 56 34 1 Senator on 5 Gallon Ram 58 23 1 Monark on 5 Gallon Ram 60 20 1 President on 55 Gallon Ram 62 34 1 Senator on 55 Gallon Ram 64 31 1 Bulldog on 55 Gallon Ram 65 20 1 Senator on 55 Gallon Drum 66 9 1 DynaMite on 1 Gallon Can Ram 67 10 Gallon Press Tank with 15 1 Booster 68 10 1 President 5 Gallon Pail Cover 69 Mix Kit Selection 70 Cartridge Fill Medium Viscosity Wide Ratio 70 Cartridge Fill High Viscosity Wide Ratio 72 Brush Grade High Viscosity Wide Ratio 74 MD2 20 ft Automatic 76 MD2 20 ft Hand Gun 77 MD2 15 ft Hand Gun Wide Ratio Moisture Lock 78 High Volume Static Mix Manifold 79 High Volume Static Mix Kit with Pump Pilots 80 Stanchion c esie um ER EGER 81 Boom Assembly 82 Technical Data 84 Graco Standard Warranty 86 Graco Information 86 309790ZAA 309790ZAA Warnings Warnings N Skin In
14. CLAMP CLAMP drum PLATE mounting WIRE assy 25 ft TEE pipe VALVE safety NIPPLE short SCREW cap SCREW cap hex head NIPPLE close WASHER lock SCREW set WASHER flat SCREW lag WASHER spring lock NUT full hex CAP end ELBOW street UNION swivel 90 FITTING nipple pipe reducing GAUGE pressure air 1 8 in npt UNION swivel 90 REGULATOR air 1 4 in npt 9 RRRR Ref No 40 41 45 46 47 48 49 50 51 52 55 56 58 64 69 75 76 77 79 80 81 82 83 84 85 87 Part No 158256 113269 161822 054123 111162 167652 238928 114363 167646 166552 238929 109495 208048 100403 113896 100270 100016 114243 156849 113915 158212 235497 160327 215238 214651 109126 184037 Description UNION swivel VALVE ball vented 500 PLATE mounting TUBE nylon 3 6 ft FITTING elbow ROD tie ram PISTON 55 gallon ram VALVE ball fluid BEAM ram CAP cylinder PLATE 55 gallon ram PACKING o ring HOSE coupled 61089 PLUG pipe VALVE control SCREW cap hex head WASHER lock VALVE check UNION adapter 90 FITTING union BUSHING VALVE check UNION adapter 90 HOSE coupled 61220 HOSE coupled 61209 17 ft HOSE coupled 72 in FITTING outlet 6 cm 9 lt ss Nm mm Oe Oe a mm mm ODO mt 309790ZAA Parts
15. ity This is typically found in the sealant and adhesive industry where special requirements for loading and pumping necessitate the use of the 8900 proportioning system Major Components The major components of the 8900 Proportioner system include the Component A or major volume metering cylinder Component B or minor volume metering cylinder Component or major volume feed supply Component B or minor volume feed supply Ratio Proportioning The A and B cylinders are positive displacement meter ing cylinders Positive displacement cylinders displace a defined volume of fluid for a given stroke length On fixed ratio units the volumetric ratio is the ratio of the area of the component A displacement cylinder to the area of the component B displacement cylinder At a 1 1 ratio the displacement cylinders are the same size On higher ratio units the component A cylinder is usually the larger of the two The ratio of the components is the dif ference in effective area between the cylinders On variable ratio units the component B cylinder has an adjustable stroke length The component A cylinder has a fixed stroke length By setting the stroke adjustment to different points on the connecting linkage you can change the stroke length of the B cylinder which changes the mix ratio You can calculate the material mix ratio from the ratio of the cylinder displacement vol ume Note that the mix ratio of the 8900 Proportioner is a
16. 1 4 f branch VALVE ball HOSE coupled 10 ft NUT jam GASKET vellumoid PLATE cover FITTING bushing pipe RETAINER siphon tube NUT retainer TUBE siphon hd agitator VALVE ball vented 750 Y 309790ZAA 9 lt N WW NH 3 CO Parts 9 1 DynaMite on 1 Gallon Can Ram Module No 570249 Ref Ref No Part No Description Qty No Part No Description Qty 235871 PUMP extruder sst 190 8 C24332 BOLT U 217298 BRACKET mounting 9 100615 BUSHING hex steel 514518 HOSE coupled 3 16 in x 3 ft 10 101885 SCREW cap sch 109125 HOSE coupled 72 in 11 102040 NUT lock hex 224908 INDUCTOR assy 1 gal 12 100086 WASHER plain 156823 UNION swivel 13 155541 UNION swivel 90 156971 NIPPLE short 14 100206 BUSHING pipe Nm N NOJAA O ND Po me aa 309790ZAA 67 Parts 10 Gallon Press Tank with 15 1 Ref No Booster 16 Module No 570037 ha 19 Ref 21 No Part No Description Qty 22 2 101946 PIN cotter sst 1 23 102325 ELBOW 90 1 24 5 156082 PACKING o ring 1 25 6 156823 UNION swivel 1 26 7 157785 UNION swivel 2 27 8 217296 FRAME pump 1 9 167682 ROD tie 3 10 207352 MOTOR air pres 1 29 11 207370 ROD connecting 1 29 12 21593
17. 113187 061134 105209 100101 100131 100133 965785 100840 Description TUBE nylon 0 375 OD 6 ft LOCKNUT 1 2 20 NF WRENCH spanner FITTING swivel 3 4 nps x 3 4 npt RING CHAIN MANIFOLD lube AIR CONTROL see page 53 U BOLT 3 8 16 UNC VALVE relief UNION swivel 1 2 14 npt x 3 4 npsm CONNECTOR tube 1 2 OD x 1 2 npt HOSE nylon 1 2 in OD 1 4 MPa 14 bar 200 psi 6 SCREW 10 32 UNF x 7 8 in SCREW 3 8 16 UNC x 1 in NUT 3 8 16 UNC WASHER lock 7 16 in BASE ELBOW 1 4 18 npt EPDM replacement part available in kit 289401 TI2763A Qty D D D x 309790ZAA 309790ZAA Parts 43 44 23 24 22 22 13 2 d 17 Be ii 25 57 45 46 47 T 19 20 21 9 L Oo A WARNI JEE esee PROPORTION le 14 LI 12 TI2761A 27 28 8 26 27 o O B CYLINDER AT o ol cssj Eee O O 5 49 50 51 TI2762 27 28 40 48 49 Parts 8900 Proportioner Variable Ratio Ret No Part No Description 46 C23269 CHAIN 9 lt Item 1 Item 2 47 C03190 RING 49 100840 ELBOW street Part Number 53 C29043 BUSHING ball 54 160327 FITTING union adapter 90 degree page 52 74 120389 FITTING tube 624545 FITTING TEE 3 4m run X 1 4f
18. 2 4 75 513754 COLLAR shaft 1 250 cs split 6 157785 FITTING union swivel 7 8 9 79 113344 UNION swivel 1 2 4 2 o o 2 e S 1S S JS 55 157191 FITTING adapter 1 IE IE IE IE 56 237112 VALVE relief 1 ae ee ee S ES 58 205439 COUPLING h hose RC bak Quantity 59 061134 HOSE nylon 6 1 1 4 1 570377 2 60 C24140 MANIFOLD lubrication 1 4 2 61 105209 SCREW cap socket head 2 cii ase 1 l 62 949666 AIR CONTROL see page 53 1 5 1 20 1 570380 1 1 63 100004 SCREW cap hex head 8 64 100131 NUT full hex 6 65 100133 WASHER lock 6 Ref 66 965785 BASE weld mount 8900 VR 1 No Part No Description Qty 67 C30021 BOLT u 2 1 CYLINDER see table above and 68 6026814 SPACER 75 od x 45 id x 50 Ig alum 8 page 52 72 120753 FITTING elbow male 90 degree 2 CYLINDER see table above and 73 590385 TUBE 3 8 in OD nylon 3 6 ft 2 2 1 102814 GAUGE pressure fluid 156172 FITTING union swivel 552272 HOSE PTFE 3 4 18 5000 psi npt m 12 C23016 COUPLING pair 13 C19854 SCREW cap socket head 14 C24016 ARM trip 15 C24422 ROD tie 16 101926 NUT locking metallic 17 C23280 8841 4 A beam assembly 18 C24420 SCREW ratio adjusting 19 C24419 PLUNGER 20 C29031 BAR uni 21 C29023 ASSEMBLY fulcrum 22 C29037 STOP unibar 23 C19852 SCREW cap socket head 24 16E287 ACTUATOR pneumatic 25 16E324 COUPLER long 26 C24418 BRACKET 3 4 valve mounting 27 C24029 VALVE 4 way 29 109212 SCREW cap socket head 30 C19829
19. 4 MD2 20 ft Automatic Wide Ratio 24H258 5 MD2 20 ft Automatic Close Ratio 24H259 6 MD2 20 ft Hand Gun Wide Ratio 24H260 7 MD2 20 ft Hand Gun Close Ratio 24H261 8 MD2 15 ft Hand Gun Wide Ratio Moisture Lock 24H243 9 High Volume Static Mix Kit with Pump Pilots 570263 N None Code E Mounting Type Selection Module Number 1 Stanchion 570071 2 Boom Assembly 246589 N None mount on 3 in 55 gallon ram 309790ZAA 9 Installation Installation Typical Installation Figures 1 3 are only guides for selecting and installing system components and accessories Contact your Graco distributor for assistance in designing a system to suit your needs Location Position the feed modules so the pump and ram are Check that the ram base is level in all directions If easily accessible Ensure that there is sufficient over necessary level the base using metal shims Secure head clearance when the ram is fully raised Refer to the base to the floor using 1 2 in 13 mm anchors the ram manual for clearance dimensions that are long enough to prevent the ram from tipping Using the holes in the ram base as a guide drill four holes for 1 2 in 13 mm anchors Key Figs 1 and 2
20. Fill Medium Viscosity Wide Ratio Module No 570248 Ref Ref No Part No Description Qty No Part No Description Qty 47 597151 FITTING elbow 48 552211 VALVE pulse pneumatic 49 593538 VALVE shuttle 1 8 npt f 10 504327 HOSE nylon 3 4 in id 50 503028 VALVE air push pull 11 504621 COUPLING hose 51 104631 KIT accessory 4 626748 BRACKET mount disp valv C24342 1 1 1 4 4 12 166590 ELBOW street 2 52 100730 BUSHING 2 1 8 8 5 552204 ACTUATOR air 8900 metered shot 6 C30021 BOLT u 13 160327 UNION adapter 90 53 104984 TEE pipe 14 175013 NIPPLE pipe 54 C19391 FITTING elbow 1 4 npt m x 1 4 od 15 512442 HOSE bulk 1 2 in nylon 3500 psi tube 16 503917 COUPLING hose 1 2 ft npt m x 56 512420 FITTING cross steel 3 8 npt 1 2 3903 57 100195 NIPPLE pipe 17 105281 UNION swivel 90 58 103656 FITTING pipe hex 18 512616 HOSE PTFE 1 4 x 18 in 1 4 npsm 59 599433 FITTING elbow male 19 500517 FITTING tee 3 4 in npt 60 501014 ACTUATOR air 1 8 npt f 20 158683 FITTING elbow 3 4 in npt 63 114372 MIXER static 1 2 npt 24 100896 FITTING bushing pipe 64 158581 COUPLING hex 25 155470 UNION swivel 90 65 948081 MIXER tri core 1 2 m x 1 2 f 26 156684 UNION adapter 66 159153 UNION swivel 27 100840 ELBOW street 67 690270 ADAPTER luer lock 1 4 in npt 32 156971 NIPPLE short 68 112012 NOZZLE needle 33 626758 MANIFOLD block 8900 meter shot 69 112019 NOZZLE needle 34 626757 BLOCK check 8900 metered sh
21. Make sure the pump begins to 1 Placea waste container under the pump bleed valve cycle and material flows from the bleed valve after located behind the displacement pump outlet FIG several cycles of the pump FIG 11 11 Using an adjustable wrench open the bleed valve counterclockwise 1 3 1 2 turn If the pump does not cycle close the air shutoff valve G adjust the air motor regulator O FiG 8 up 5 psi 34 kPa 0 3 bar and repeat step 2 Never adjust the regulator by more than 5 psi 34 kPa 0 3 bar increments A 3 Operate the pump until it moves smoothly in both directions with no air popping or erratic movement then close the air motor shutoff valve G 1 Jl T d E y J ATR LO 4 Close the bleed valve FIG 11 Bleed Valve Fic 11 20 309790ZAA Load Component B Follow the procedure for the type of supply equipment being used Pneumatic Pail Ram and Piston Pump 1 2 Close all air regulators and air valves Set the pail ram air regulator D to 40 psi 0 28 MPa 2 8 bar FIG 12 Push the ram directional lever C to the UP position and let the ram rise to its full height When ram is fully raised apply a thin coating of lubricant to the ram plate drum seals Remove the component B pail cover If the material has separated carefu
22. Manually activate the limit valve item 26 on page 48 to cause the 4 way valve to shift fully relieving pressure within the proportioner 7 If you suspect that the nozzle or hose is completely clogged or that pressure has not been fully relieved after following the steps above very slowly loosen the tip retaining nut or hose end coupling and relieve pressure gradually then loosen it completely and clear the nozzle or hose 309790ZAA 27 Operation Dispense Mixed Material CAUTION Make sure the component B relief valve is operational and free from blockage at all times See manual 308547 If the relief valve fails the overpressure rupture disc opens and component B is diverted to a waste con tainer mounted on the ram base plate 8900 Proportioner with Static Mix Chamber Kits 1 Load the material See page 19 2 Onthe variable ratio machine set ratio see page 14 On the fixed ratio machine proceed to step 3 3 Open the pump A and pump B air shutoff valve S FIG 20 28 4 Adjust the component A and component B air regu lators F and O until both outbound gauges H and I show the desired pressure FIG 20 21 5 Trigger the gun to dispense mixed material Adjust the Flow Rate The dispensing flow rate for the system is controlled by the material pressure of component A and component B The air pressure on pump A determines the flow rate from the material outlet Per
23. No material inlet pressure Verify No air supply to limit valve Verify Meter will not move Material inlet pressure not high enough to drive meter Verify low pressure on the gauges before increasing 4 way ball valve orientation incorrect Check fix Dispense valve closed Open Blockage in material hose Depressurize system and repair Blockage in meter assembly Depressurize system and repair Material leaking from meter end caps Meters not balanced Worn seals Replace End caps loose Improper operation of supply pumps Inadequate material supply to pumps Hand tighten with wrench provided Check for proper operation of mate rial supply pumps Each should have adequate material supply Reason ably constant and balanced meter inlet and outlet pressures indicate proper pump function If flow rate is increased by increasing A pump pressure increase B pump pressure proportionally to balance meter inlet and outlet pressures Meter outlet pressure too high metering inaccurate decreased flow rate non uniform mix streaking Curing material in the mixer or block age of either mixer inlet port check valves injector valves plugged Clear blockage Incorrect ratio check and reduced flow rate Material may be bypassing rather than flowing through the meter Check for leakage in meter seals and cups Inaccurate metering 40 Air in
24. SCREW cap socket head 31 111303 NUT hex 32 100214 WASHER lock 33 C23276 MONITOR scale 34 C19798 SCREW cap socket head 35 100018 WASHER lock spring 36 100321 NUT 38 C24014 VALVE limit 39 C24042 FITTING union assembly 40 C24417 STUD 41 16E321 COUPLER 3 4 in sq x 5 8 in sq 43 100847 FITTING lubrication 44 C24442 PLATE designation 45 C29034 TOOL spanner wrench EPDM replacement part available in kit 289401 D ND OO D BR BB D D D D ND O ND ND D O1 BB BR BR 67 66 72 73 74 60 61 62 63 64 65 Top View 50 309790ZAA 75 43 75 22 33 34 20 21 53 19 7 23 35 MT 7 D 7 e 1i E E 18 _ 4 Ge a 14 44 ae EX a7 _16 15 13 13 12 27 27 30 31 32 7 49 54 54 9 16 570378 and 570380 2 570377 1 309790ZAA Parts 51 Parts Cylinder Assemblies Ref No Part No Description Qty ref nos 7 and 14 FR 1 and 2 VR 106 15C181 SPACER 246558 only 1 C23431 SPACER 570366 only Part No 246558 C23460 SPACER 570367 only Model 246557 only C23398 SPACER 570369 only C05031 SPACER C24145 only Part No 570366 107 15C182 PACKING cup 246558 only 2 Models 570373 and 570374 only C23318 PACKING cup 570366 only C23350 PACKING cup 570367 only Part No 570367 C23282 PACKING cup 570369 only Models 570372 570375 and 570377 only C05032 PACKING cup C24145 only 108 15C183 RING backup 246558 only 2 Part N
25. always follow this procedure to relieve pressure in the tank at the following times e Before you check or service any part of the spray system e Before you loosen or remove the pressure tank cover or fill port e Whenever you stop spraying Air inlet valve AA Drain cock fitting Fic 27 309790ZAA Operation Shut off the air supply to the tank by closing the air inlet valve Refer to FIG 27 Open the drain cock fitting by turning it counter clockwise Wait until there is no air escaping through the drain cock fitting before removing the cover or opening the fill port Leave the drain cock fitting open until you have rein stalled the cover or fill port Fill port cap 03089C 31 Operation Filling Component B Pressure Tank If you are using a pressure tank to supply component B check the tank level with a metal or plastic rod whenever the Component A drum is changed To add component B to the tank follow the procedure below 1 Close the tank air supply shutoff valve Fic 28 2 Relieve pressure in the tank see page 27 3 Open the fill port cap on top of cover CAUTION Do not leave the pressure tank open Component B will crystallize if exposed to the moisture in the air The tank cover is normally removed only for tank cleaning Arrow points toward tank Component B air supply valve TAS
26. fluid Read fluid manufacturer s warnings e Wear appropriate protective clothing gloves eyewear and respirator 4 309790ZAA Warnings RS CH uim Equipment Misuse Hazard Equipment misuse can cause equipment to rupture malfunction or start unexpectedly and cause serious injury e This equipment is for professional use only Read manuals tags and labels before operating equipment Use equipment only for its intended purpose If you are uncertain call your Graco distributor Do not alter or modify equipment Use only genuine Graco parts and accessories Check equipment daily Repair or replace worn or damaged parts immediately Do not exceed maximum working pressure of lowest rated system component e Use fluids and solvents that are compatible with equipment wetted parts See Technical Data sec tion of all equipment manuals Read fluid and solvent manufacturer s warnings e Route hoses away from traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 180 F 82 C or below 40 F 40 C Do not kink or overbend hoses or use hoses to pull equipment Comply with all applicable local state and national fire electrical and other safety regulations e Donotuse excessive drum separation air pressure as the drum could rupture Make sure the drum is not damaged and the ram plate is free to exit the drum before applying air pressure
27. man Fl P a m ifold and feed pump assemblies should be off d H 3 Open the feed pump main air valve S This allows A D the air supply to feed pump assemblies E i gt 4 Adjust the component B supply pump air regulator F to allow smooth pumping action Continue until component B flows from the dispense gun into the Bleed Valve waste container FIG 16 The minor or component B side of material is filled 2 Slowly open the component B air motor shutoff first to minimize waste during initial startup valve E FIG 15 Make sure the pump begins to cycle and material flows from the bleed valve after 5 Adjustthe component A air regulator O to allow several cycles of the pump FIG 16 smooth pumping action If the pump does not cycle close the air shutoff 6 Pump until component A and component B flow valve E adjust the air motor regulator F Fic from the gun into the waste container When the 17 up 5 psi 34 kPa 0 3 bar and repeat step 2 material is bubble free all air has been purged from Never adjust the regulator by more than 5 psi 34 the system kPa 0 3 bar increments 7 Turn off air supply valve S 3 Operate the pump until it moves smoothly in both 8 Close dispense gun directions with no air popping or erratic movement then close the air motor shutoff valve E FiG 15 9 The 8900 Proportioner is now filled with compo nents A and B and ready for operation 4 Close the bleed valve FIG 16
28. pump A and B wet cups 2 3 full with Graco T S L fluid throat seal lubricant or lubricant com patible with material being pumped ISO pump oil is used with moisture sensitive com ponent B 5 Close turn fully counterclockwise all air regulators 6 Connect the 3 4 in 19 mm ID x 10 ft 3 05 m air hose provided to your air supply Do not use a restrictive quick disconnect The air supply pressure must be consistently above the pressure you set on the main air motor regulator GRACO G m Ecce Wet Cup TI3263Ax FiG 7 18 309790ZAA Load Component A 1 Make sure all air regulators on proportioner module are fully closed 2 Open the main air supply shutoff valve A FIG 8 3 Place the ram lever P FiG 10 in the UP position CAUTION As the ram rises make sure hoses do not catch on any components If a hose catches immediately stop the ram move lever to NEUTRAL position and correct the problem Lower the ram if necessary to redirect hoses 4 Slowly turn the ram air regulator R clockwise until the ram begins rising Fic 8 5 When ram is fully raised apply a thin coating of lubricant to the ram plate drum sea
29. the drum It is recommended that you check and refill the component B at the same time 1 Close the air motor shutoff valve 2 With the ram lever PP in the neutral position FIG 25 adjust the ram regulator R FIG 26 to 0 psi FIG 25 3 Place the ram lever PP in the UP position FIG 26 Fic 26 Do not use excessive drum separation air pressure Make sure the drum is not damaged and the ram plate is free to exit the drum Read warnings page 5 4 Push and hold the ram separation air button PPP 5 Adjust the ram regulator R to approximately 10 15 psi 69 103 kPa 0 7 1 bar or until the ram plate begins to rise 30 Continue to hold the drum separation air button PPP just enough to keep the drum from rising with the ram plate Follow the procedure to load material pages 19 24 You only need to lubricate the ram plate tire seals the first time you load material 309790ZAA Changing Component B Pail If you are using a ram and pump to supply component B the procedure to change the pail is the same as changing the Component A drum except that you use the controls on the back of the pail ram Pressure Relief Procedure For component B tank models only WARNING PRESSURIZED EQUIPMENT HAZARD The pressure tanks remain pressurized until pressure is manually relieved To reduce the risk of serious injury from pressurized fluid or accidental spray from the gun
30. 0 PUMP displ recip 1 30 13 221170 HOSE coupled 061260 3 ft 1 Si 14 236150 TANK high pressure 10 gallon 1 uS 10 30 32 2 5 11 26 2 Tp HJ REBIDEN 68 Part No 236662 236677 501603 512484 620198 100101 100133 100131 100016 100022 150707 H45010 100896 160327 214656 109126 158491 107142 15 Qu 10 lex 9 a 195 aan Description AGITATOR heavy duty 10 gallon KIT repair VALVE check 1 2 in npt mbe sst tf VALVE ball sst PLATE mounting SCREW cap hex head WASHER lock NUT full hex WASHER lock SCREW cap hex head PLATE designation HOSE fluid nylon 1 2 in 13 mm ID 1 2 npsm fbe 10 ft 3 05 m long FITTING bushing pipe UNION adapter 90 HOSE coupled 61209 10 ft HOSE coupled 10 ft FITTING nipple VALVE ball vented 31 Fe i 6 16 Qty 1 1 1 1 1 4 4 4 2 2 1 1 QD nn 309790ZAA 10 1 President 5 Gallon Pail Cover Module No 570264 Ref No 1 3 4 5 Ref Part No Description Qty No 903295 PUMP 10 1 President sst 1 6 100035 SCREW machine panhead 1 7 206755 CHAIN 1 8 165096 PLUG 1 Parts ANS c Detail O 309790ZAA Part No Description Qty 165516 PACKING o ring 1 101962 SCREW set sch 2 100220 SCREW thumb 3 21 20 28 29 HHH 30 21 acsi niim 22 uj 12 14 15 16 j 10 9 24 O 69 Parts Mix Kit Selection Cartridge
31. 0ZAA Parts 81 Parts Boom Assembly Module No 246589 Ref Ref ENT No Part No Description ty No Part No Description Qty 10 622070 SBACHET bom 9 1 947039 FRAME boom swivel 55 gal 1 44 166590 ELBOW street 2 2 158383 FTIING union adapter straight 1 13 103473 STRAP tie wire 3 3 157262 WASHER plain 4 14 570071 BASE stancion mounting 1 d ooo MIPEEE redueing 2 15 606937 FITTING bulkhead 1 2 i E anor 16 100056 NUT jam hex 1 6 155495 UNION swivel 907 1 17 202966 FITTING union adapter 1 7 156175 FITTING union swivel 2 18 100896 FITTING bushing pipe 1 9 500946 HOSE 1 in mbe 1 20 166999 FITTING elbow street See Detail A M RUE Beje 5 Te Ha See Detail B 2 20 17 D Rs PR Detail C 4 ENN ee 1 9 1 i FUN i Ver is i mon 9 ioe i con 6 F veu i F LIU EN 1 igs HI ies TES See Detail C o o o o Detail A gu _ 14 Detail B 82 309790ZAA Parts 309790ZAA 83 Technical Data Technical Data Maximum system working pressure 2000 psi 13 8 MPa 138 bar Maximum air input pressure 100 psi 0 7 MPa 7 bar Main air inlet size 8900 Proportioner 3 4 npsm f 8900 Proportioner outlet size Component A Pu
32. 24039 C07067 or 289401 C07069 Trunion 3 16 in inside port 4 Way Valve 5 8 in C24029 C07067 or 289401 C07068 Trunion 5 8 in inside port 4 Way Valve Repair Kits Cross Reference 289401 Repair Kit C07067 Qty Description EDPM 8900 Cylinder Repair Kit 15R207 C24032 4 PACKING o ring 15R208 C24035 4 PACKING o ring 15R209 C24036 4 PACKING o ring 15R210 C24040 1 PACKING o ring 15R211 103611 2 PACKING o ring 15R214 2 PACKING o ring C24031 C24031 4 SEAL C24037 C24037 2 BUSHING C24038 C24038 4 RING backup This part is equivalent to 105802 309790ZAA 85 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco
33. 30 Part No C20487 113332 155541 276025 102637 109495 100101 100133 237569 100505 158979 114363 Description FITTING nipple hex VALVE ball vented 750 UNION swivel 90 CLAMP SCREW cap PACKING o ring SCREW cap hex head WASHER lock WIRE assy 25 ft FITTING bushing pipe FITTING nipple pipe reducing VALVE ball Parts 9 lt A AR oo lt 65 Parts 20 1 Senator on 55 Gallon Drum Module No 570309 Ref No PartNo 1 570308 2 207408 3 237579 6 514944 7 159842 8 100380 9 501764 10 237309 11 208536 12 158491 13 237578 14 215239 22 160327 23 160032 66 Description PUMP 20 1 Senator Dura Flo 750 ELEVATOR stationary KIT repair VALVE needle sst 1 2 MF 6000 ADAPTER BUSHING pipe FITTING elbow 90 1 in npt f x 1 in n COVER drum COUPLER line air FITTING needle SUPPORT cover assy sst HOSE coupled 61220 UNION adapter 90 NIPPLE Ref No 24 25 26 28 29 31 32 33 34 35 36 38 39 40 41 42 43 44 45 DJ A LAPS Part No 102644 157785 214656 102471 102021 205349 162449 157785 180916 214037 109126 187614 159446 15C321 100896 15C322 190999 238161 113218 aa Description VALVE ball UNION swivel HOSE coupled 61209 10 ft SCREW cap hex head NUT lock HOSE coupled 61120 15 ft FITTING nipple reducing FITTING union swivel FITTING tee 3 4 m run x
34. 57 58 59 63 65 66 67 68 70 71 72 73 74 75 76 77 79 80 Part No 101533 190265 238925 166552 206726 054123 190256 100680 101566 100023 114320 115901 160327 235497 100896 H45010 214656 109126 155470 158491 Description WASHER spring lock SPACER PISTON ram 5 gallon CAP cylinder BASE and cylinder TUBE nylon 3 7 ft CLAMP support SCREW cap hex head NUT lock WASHER flat FITTING connector 1 8 npt f TRIM edge protection UNION adapter 90 VALVE check FITTING bushing pipe HOSE fluid nylon 1 2 in 13 mm ID 1 2 npsm fbe 10 ft 3 05 m long HOSE coupled 61209 10 ft HOSE coupled 10 ft UNION swivel 90 FITTING nipple Qty NO 309790ZAA Parts 72 73 74 80 75 22 57 309790ZAA Parts 34 1 Senator on 5 Gallon Ram See Graco Manuals 308026 and 306838 Module No 965597 Ref No Part No 1 222769 2 100468 3 100133 4 222812 7 101154 10 102556 12 107144 15 184150 17 184147 22 206726 23 101533 24 166552 25 113208 26 113896 29 160107 30 054123 34 110318 58 Description PUMP senator 4 5 cm SCREW cap hex head WASHER lock PLATE wiper 5 gallon PIN driv lok RIVET blind SCREW cap hex head SPACER rod elevator SHIELD 5 gallon ram BASE and cylinder WASHER spring lock CAP cylinder
35. 790ZAA Description BODY valve SEAL PACKING o ring BUSHING FITTING connector PACKING o ring PACKING o ring 405 406 407 Qty Ref No Part No 408 C24037 409 C24038 410 103611 411 C07068 412 C24040 413 C24041 414 100133 415 C19839 EPDM replacement part available in kit 289401 Description BUSHING RING backup PACKING o ring BALL passage PACKING o ring CAP end WASHER lock SCREW cap socket head 404 407 406 405 Parts 9 lt AA NANT 55 Parts Pump Feed Module Selection for Component A or Component B 20 1 President on 5 Gallon Ram See Graco Manuals 308026 and 306838 Module No 965571 Ref No 4 13 22 24 27 35 36 37 42 43 44 45 47 48 49 51 52 53 54 56 Part No 237207 222812 102556 156823 184147 113269 155865 237569 156971 104984 113286 160701 237562 113208 113896 104765 110318 110319 160107 Description PUMP President 20 1 PLATE wiper 5 gallon RIVET blind UNION swivel SHIELD 5 gallon ram VALVE ball vented 500 UNION adapter WIRE assy 25 ft NIPPLE short TEE pipe VALVE safety ELBOW street SUPPORT pump FITTING tube VALVE control PLUG pipe headless REGULATOR air 1 4 in npt GAUGE pressure air 1 8 in npt NUT cap 9 Nm mm mm BB Ref No 55 56
36. C22064 VALVE 2 318 C24007 SPACER 1 319 C24051 MANIFOLD 1 320 100079 WASHER lock spring 2 303 304 305 306 d NS ope A D Un IOS l5 ial 3l ET l5 i r 319 Faw fa 319 AL iw 309 307 SS 308 1 IL 4 ni Tom 0 0 pe q rd rj L 309790ZAA Part No C19977 C24012 C20852 C19835 C24017 C24009 C20068 C24018 C24019 C19146 C24020 C19264 C24016 Description SCREW cap VALVE 4 way FITTING plug 10 32 SCREW cap socket head ROD trip valve SPRING compression PIN spring COLLAR stop INDICATOR scale SCREW mach slotted round head COLLAR clamp PLUG pipe plug 1 4 in ARM trip 9 lt Parts 53 Parts Air Control Ref No Part No Description Qty ref no 41 F
37. Instructions Parts G GRACO 8900 Proportioner 309790ZAA ENG Configured product offering for dispensing fixed or variable ratio of two fluids For professional use only Not approved for use in European explosive atmosphere locations 2000 psi 13 8 MPa 138 bar Maximum Working Pressure Save these instructions Important Safety Instructions e Read all warnings and instructions in this manual See page 8 for pump model numbers ratios and working pressures WARNING NC ca Jol T TI2761A amp LJ a Fixed ratio proportioner shown HO03 PROVEN QUALITY LEADING TECHNOLOGY Contents WarningS eo i Rr mama ete Suede 4 Theory of Operation 6 US 6 Major Components 6 Ratio Proportioning 6 System Components and Operation Overview 6 Models LET 8 Installation IA RII 10 Typical Installation 10 Location 25s tre ns 10 Ground etas tt RC LC Tuer doo pans 12 IUSH cst asta m ease hoe eth a o S e na e
38. R 62 VR 212 103475 TEE 1 2 npt 1 213 100122 NIPPLE 1 2 14 npt 2 Part No 949666 214 214848 LUBRICATOR air line 1 215 106149 FILTER air 1 2 npt 1 Ref 216 172124 NIPPLE 1 2 14 x 3 8 18 npt 1 No Part No Description Qty 219A 551206 WARNING LABEL 1 201 626086 BRACKET 1 2204 551207 INSTRUCTION LABEL 1 202 624225 AIR MANIFOLD 1 221 158990 AIR MANIFOLD 1 203 157191 ADAPTER 3 222 158491 NIPPLE 1 2 14 npt 1 204 206197 AIR REGULATOR 1 2 x 3 4 npt 2 223 155495 UNION 90 swivel 1 4 npsm x 3 8 2 205 100840 ELBOW 1 4 18 npt 2 npt 206 160430 GAUGE air pressure 2 224 162453 NIPPLE 1 4 npsm x 1 4 npt 2 207 1554701 UNION 90 swivel 1 2 14 npsmx 3 225 101748 PLUG 3 8 18 npt 2 1 4 14 npt 226 100361 PLUG 1 2 14 npt 1 208 105170 SCREW 1 4 20 UNC x 2 in 3 227 C19411 CONNECTOR 3 8 tube x 3 8 npt 1 209 100015 NUT 1 4 20 UNC 5 228 106285 U BOLT 1 4 20 UNC 2 210 100016 WASHER lock 5 229 C19394 ELBOW 90 3 8 tube x 3 8 npt 1 211 110225 VALVE 2 way vented 1 2 14 npt 2 208 CS 225 al hi 220 219 i 223 223 227 222 3i WARNING w S900 Z gt GRACO K P K D D a si 229 gt elf TI Z p S mm ac TE HTM CE NO ARR YA l 206 8 213 204 216 D 211 543 225 222 211 207 bu a 203 224 gla 210 549 215 228 Sog 207 54 309790ZAA 4 Way Valve ref no 25 FR 27 VR Part No C24029 Ref No Part No 401 C24030 402 C24081 403 C24036 404 C24033 405 C24034 406 C24035 407 C24032 309
39. Supply Z Component A Supply W Component B Injector Valve FIG 3 309790ZAA ti16737a 77 Installation Ground A WARNING y The system must be properly grounded Read warn ings page 5 Follow the instructions below Pump use the ground wire and clamp supplied There are two styles of ground connections on pump air motors If you have the ground screw a shown in FIG 4 King air motor only order part no 222011 ground wire ring terminal and clamp assembly b To install 222011 remove the ground screw a and insert it through the eye of ring terminal c then tighten ground screw back into air motor as shown in FIG 4 Connect the other end of the wire to a true earth ground FiG 4 Ground Screw King air motors only If you have the ground screw d shown in FIG 5 loosen the grounding lug locknut g and washer f Insert one end of the ground wire e into the slot in lug d and tighten the locknut securely Connect the other end of the wire to a true earth ground Order 237569 ground wire and clamp assembly gore WS Fic 5 Ground Screw 12 Air and fluid hoses use only electrically conductive hoses with a maximum of 500 ft 150 m combined hose length to ensure grounding continuity Check the electri cal resistance of your air and fluid hoses If the total resistance to ground exceeds 29 megohms replace the hose immediately Air compressor follow manufactu
40. achine per 100 parts component A by weight Compare the weight ratio obtained to the desired weight ratio Repeat to obtain several successful ratio checks Put new mix elements in the gun and reconnect the hoses to the gun 309790ZAA Operation 9 Ration check is complete and the unit is ready for operation Ratio Check Example Conversion Formula Parts by Volume PBV to Parts by Weight PBW PBV component B Specific gravity component B PBV component A x Specific gravity component A X 100 X X 100 Parts component B by weight Ratio Check Example component B sample weight LESS container weight X 100 PRODUCT component A sample weight LESS container weight PRODUCT Parts component B per 100 parts component A Manufacture s specified weight ratio 2 4 1 or 100 25 Weight of component A in ratio check is 245 grams Weight of component B in ratio check is 61 2 grams 61 2 divided by 245 equals 2497 61 2 245 2497 Three ratio checks are recommended to ensure accuracy at final setup The presence of any air visible or not vis ible in the material or system will cause inaccurate ratio checks If the ratio check cannot be made with repetitive accuracy review air bleed procedures Some materials contain substantial amounts of entrained air due to manufacturing transportation system Setup or drum change Air must be removed by de gassing recirculation or self removal over time before accurate meteri
41. ail C 309790ZAA Parts Parts Cartridge Fill High Viscosity Wide Ratio Module No 570318 Ref Ref No Part No Description Qty No Part No Description Qty 29 C12509 TUBE nylon 30 30 503028 VALVE air push pull 1 31 157191 FITTING adapter 4 32 596832 FITTING tee tube 1 33 501014 ACTUATOR air 1 8 npt f 2 34 103656 FITTING pipe hex 1 1 2 5 1 552204 ACTUATOR air 8900 metered shot 2 626748 BRACKET mount disp valv C24342 3 103374 SCREW machine rdh 4 100896 FITTING bushing pipe 5 156877 NIPPLE long 6 7 8 9 105192 SCREW cap hex head 35 593538 VALVE shuttle 1 8 npt f 36 552211 VALVE pulse pneumatic 37 C19391 FITTING elbow 1 4 npt m x 1 4 od tube 38 104631 VALVE foot 626757 BLOCK check 8900 metered shot 626758 MANIFOLD block 8900 meter shot 166590 ELBOW street 10 513375 MIXER pipe sst 3 4 16 4 in 2 el 11 100349 FITTING elbow 12 160032 NIPPLE 40 626760 MANIFOLD ratio check 8900 shot 1 1 4 1 1 1 1 1 1 2 3 1 13 552208 VALVE ball 3 way 1 42 H55033 HOSE bulk 1 2 in nylon 5600 psi 14 100206 BUSHING pipe 2 47 100133 WASHER lock 15 552205 MIXER pipe sst 1 4 4 2 in 24 el 2 48 100131 NUT full hex 16 100840 ELBOW street 4 50 104172 FITTING tube 17 157350 ADAPTER 3 8 npt x 1 4 npt 2 51 512281 rm Le 1 4 od x 1 8 in 18 205324 HOSE coupled 61120 1 ft 1 19 162449 FITTING nipple reducing 1 94 156971 NIPPLE short 20 100040 PLUG pipe 1 55 233415 KIT ac
42. ame 13 Setup ee US ile cse ld t e ae 14 Set the Ratio variable ratio models only 14 Output Charts Ratio Settings 15 Before You Load Material 18 Load Component A 19 Prime Pump 20 Load Component B 21 Prime with Component B 24 Fill the 8900 Proportioner with Material 24 Operation 27 Pressure Relief Procedure 27 Dispense Mixed Material 28 Changing Component A Drum 30 Changing Component B Pail 31 Filling Component B Pressure Tank 32 Daily Procedures 34 Troubleshooting 36 8900 Proportioner Operating Pressures 36 Air Supply Troubleshooting Chart 37 Pump Troubleshooting Overview 38 Troubleshooting Guide Feed pumps 39 Troubleshooting Guide 8900 Proportioner 40 Troubleshooting Guide Manifold Mixer 41 Preventive Maintenance 42 Service and Repair 43 Repair the Cylinder Fixed Ratio 43 Replace Air Valve 45 Disassemble Fluid Valve 46 2 PAS feremus uua Mis Gre E aaa 48 8900 Proportioner Fixed Ratio 48 8900 Proportioner Variable Ratio 50 Cylinder Assemblies
43. arts Parts 8900 Proportioner Fixed Ratio Item 7 Item 14 Part Number Sl 2182 l8 lg lv lv lo oS olo lo jo it ISIN INIS Fixed Assembly S JO l Ratio No Quantity 1 1 570371 2 1 1 24C972 2 2 1 570372 1 1 2 5 1 570373 1 1 4 1 570374 1 1 5 1 570375 1 1 9 1 246557 1 1 1 10 1 570376 1 1 Ref No Part No Description Qty 1 C24016 ARM trip 1 3 187877 TUBE gauge 2 4 102814 GAUGE fluid pressure 4 5 624545 T FITTING 3 4 npt m x 1 4 npt f 4 6 157785 UNION swivel 3 4 nps x 3 4 npt 4 7 CYLINDER see table above see 1 page 52 8 C19411 CONNECTOR 3 8 npt x 3 8 tube 1 9 C24042 UNION includes 9a 2 9a 105802 O RING fluoroelastomer 2 10 110343 SCREW 1 2 13 UNC x 1 75 in 1 11 C23016 COUPLING 1 12 C24013 SPACER 4 13 C24053 COUPLING 1 14 CYLINDER see table above see page 52 15 16E304 COUPLING 1 17 552272 HOSE 3 4 npt 4000 psi 28 MPa 2 276 bar 19 100214 LOCKWASHER 4 20 C19829 SCREW 5 16 18 x 2 5 in 4 21 111303 NUT hex 4 22 C24052 BRACKET valve mounting 2 23 109212 SCREW 3 8 24 x 3 4 in 8 24 16E287 ACTUATOR pneumatic 1 25 C24029 VALVE 4 way 2 26 C24014 VALVE limit 1 27 120753 ELBOW 90 1 4 npt x 3 8 in tube 1 48 Ref No 28 30 31 32 38 39 40 41 42 43 44 45 47 48 49 50 51 52 57 Part No 590385 101926 C29034 156172 C03190 C23269 C24140 949666 C30021 237112 113344
44. cessory ratio check 21 155699 ELBOW street 1 98 157785 UNION swivel 22 159239 FITTING nipple pipe reducing 1 60 160327 UNION adapter 90 23 102646 VAVLE ball 1 61 166466 TEE pipe female 24 158491 FITTING nipple 1 2 npt 1 63 104984 TEE pipe 25 C26088 VALVE cone extension 1 64 120753 FITTING elbow male 90 26 C26086 STOP cone assembly 1 65 100008 SCREW cap hex head 27 151249 NIPPLE pipe 1 66 100176 BUSHING hex 28 112698 ELBOW male swivel 1 68 512616 HOSE coupled 61120 1 5 ft f 69 100615 BUSHING hex ND D D D HO D D ND D OO 72 309790ZAA Parts See Detail A 54 97 Detail C See Detail C This view rotated 90 for clarity 161514 9 1314 1819 Detail A 309790ZAA 73 Parts Brush Grade High Viscosity Wide Ratio Module No 570358 Part No 159841 114112 100030 626748 552204 C30021 155699 100615 159801 504327 504621 166590 160327 175013 512442 503917 105281 512616 500517 158683 100896 155470 156684 100840 512912 156971 626758 626757 C26088 C26086 133374 105192 C24017 C20068 C24018 C24020 120753 513066 C12509 597151 552211 593538 503028 212099 100730 104984 C19391 512420 100195 Description ADAPTER FITTING connector f
45. chieved by volumetric ratio of component A to compo nent B and not by weight These two ratios are often dif ferent depending on material properties System Components and Operation Overview Feed Systems Feed Pumps Load the Feed Pumps and Proportioner The A and B feed pumps cylinders must completely fill prime on both strokes to ensure accurate material dis placement With high viscosity materials it is difficult for material to flow into the pump Individual feed pumps are used to supply these materials under pressure to the 8900 Pro portioner When air is trapped in the feed system due to improper loading a condition called cavitation occurs If cavitation occurs part of the downstroke will be used to fill the vacuum before any material is actually dis placed Since the total stroke length is used to calculate mix ratio this may result in an off ratio condition To prevent cavitation with higher viscosity materials both cylinders are pressure fed The A pump is pressur ized by a pneumatic ram supply unit applying a down ward force on a 55 gallon plate fitted into the drum A shovel action pump fluid inlet further aids in pump prim ing Component B is delivered to the B pump by pres sure fed 5 or 55 gallon supply modules depending on the volumetric ratio of the material Pneumatic ram assisted feed pumps may not be required for lower viscosity materials Feed Systems Alternative Feed Supplies Header or o
46. component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brou
47. e and counterclockwise to increase the amount of component B 11 If the ratio is correct tighten the fulcrum nut and reattach hoses 7 to the dispensing gun 33 Operation Daily Procedures Daily Start up Procedure 1 8 Perform daily maintenance operations including a Check oil level in main air lubricator b Drain any water from filter in main air line c Tighten pump packing nuts daily the first week weekly thereafter d Visually inspect system for leaks e Grease zerk fittings Turn air pressure to the unit ON Check ratio on variable ratio models Steps 4 and 5 are applicable only to mix manifold models Open the coupled ball valves push up Ensure that the component A purge ball valve is closed Place a material waste container under the gun out let and open the dispense gun Dispense material until well mixed material is being dispensed The system is now ready to operate Daily Shut down Purge Procedures Component A Purge 1 2 3 34 Close the coupled ball valves push down Open the component A purge ball valve Hold the dispense gun over a material waste con tainer Hold the dispense gun open until only component A is evident Close the component A purge ball valve Close the main air valve located under the meter base plate to remove air pressure from the meter After the system is purged do not open the dis pense gun until the next system operat
48. ecause of the viscosity difference between the two materials most of the balancing effect comes from adjusting the component A pressure For ratios higher than 1 1 the component B pressure should be set only as high as necessary to avoid cavitation at the desired flow rate For 1 1 ratio there is equal balancing from component and component B pressure If either the A or B pump does not completely fill with material on intake the failing pump s material output is interrupted at the beginning of the next stroke This is referred to as cavitation Pump A cavitation is detected by observing the inlet pressure gauges on pump A and pump B immediately after changeover When cavitation occurs the propor tioner pump outlet pressure gauge drops and the pump A outlet pressure gauge shows an increase in pressure as described previously B pump cavitation is detected by observing the B pump inlet pressure gauge immediately after pump top changeover When cavitation occurs the B pump outlet pressure gauge drops If the amount of cavitation is moderate the pressure gauges return to their normal readings at some point during the downstroke of the failing pump During pump A cavitation the pressure drop may cause a noticeable reduction in flow rate at the dispense gun Additionally the interruption in the pump A material out put may cause component B rich material to dispense which may appear as poorly mixed material During B pump cavi
49. egulator Motor icing warm up Check air filter and lubrication Ram fails to move up and down Lack of air pressure Turn on or increase air supply pres sure to ram Ram failure Check and rebuild Material leaking past follower plate seal small amount of leakage is nor mal Too much ram pressure Reduce ram down pressure on ram air pressure Worn wiper seals Replace Dented container Straighten or replace container 309790ZAA 39 Troubleshooting Troubleshooting Guide 8900 Proportioner Problem Cause Solution Inconsistent material mix Material inlet pressures are not set correctly Erratic feed pump Follow flow rate procedures and ram feed pump troubleshooting guide Mix elements not assembled cor rectly or need to be replaced Fix or replace Cylinder cups are bypassing mate rial Replace cylinder cups Material outlet hoses are not sized correctly pressures not balanced Call Graco Tech Service 800 543 0339 Material ball valves are bypassing Rebuild replace Insufficient air supply to material sup ply pumps Purge valve open if applicable Verify consistent air supply Close during operation Meter pressures never change Meter will not shift at the end of the stroke Broken material gauge s Replace Limit valve not working correctly Rebuild replace see page 45
50. em if nec 1 Onthe ram mounted component A supply units you essary must remove the drum ram plate to immerse the A pump in a solvent pail To remove the plate 4 Remove the solvent pail s from the pump inlets a Disconnect the blow off air line from the ram 5 Operate the pump s at low pressure to remove plate excess solvent 6 Reinstall the drum or pail ram plates b Disconnect the tie rod nuts from the ram cross beam c Remove seal plates between the pump and ram d Loosen ram tie rods from plate and remove plate e lfapail ram is used with the component B sup ply remove the pail plate by loosening the 2 set Screws f Position the solvent pail so the pump inlet is in the solvent Use solvent that is compatible with the equipment wetted parts and the material you will dispense g Support the ram s so that the pump inlet and piston will not hit the base plate or pail bottom h Make sure both component A and component B outlet hoses are open 309790ZAA 13 Setup Setup WARNING M DIANE Read warnings pages 4 5 before operating equip ment Set the Ratio variable ratio models only Adjust ratio The ratio of this unit is produced partially by the differ ence in the area of the metering cylinders and partially by the position of the adjustable fulcrum point in the Uni bar linkage assembly With the fulcrum point in the cen ter each meter cylinder strokes 3 in 10 16 cm
51. emale BUSHING BRACKET mount disp valv C24342 ACTUATOR air 8900 metered shot BOLT u ELBOW street BUSHING hex steel UNION swivel 90 HOSE nylon 3 4 in id COUPLING hose ELBOW street UNION NIPPLE pipe HOSE bulk 1 2 in nylon 3500 psi COUPLINE hose 1 2 npt m x 1 2 3903 UNION swivel 45 HOSE PTFE 1 4 x 18 ft 1 4 npsm FITTING tee 3 4 in npt FITTING elbow 90 FITTING bushing pipe UNION swivel 90 UNION adapter ELBOW street MUFFLER polyethylene 1 2 npt NIPPLE short MANIFOLD block 8900 meter shot BLOCK check 8900 metered shot VALVE cone extension STOP cone assembly SCREW machine rdh SCREW cap hex head ROD trip valve PIN spring COLLAR stop COLLAR clamp FITTING elbow male 90 TUBE 3 8 in OD nylon TUBE nylon FITTING elbow VALVE pulse pneumatic VALVE shuttle 1 8 npt f VALVE air push pull KIT accessory BUSHING TEE pipe FITTING elbow 1 4 npt m x 1 4 od tube FITTING cross steel 3 8 npt f NIPPLE pipe O1 D D D ND OO ND ND PR 4 4 O1 ND R I OT UT Ref No 58 59 60 63 54 65 66 67 68 69 70 71 72 73 74 75 76 77 79 80 82 83 84 85 86 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 Part No 103656 599433 501014 114372 158581 948081 159153 690270 112012 112019 205324 164672 162449 159239 552208 100206 552205 626760 102646
52. er strokes 3 in In this center position the dispense ratio is the same as the meter cylinder ratio The ratio is adjust able from 1 1 to 20 1 depending on the location of the fulcrum point and cylinder size There are three machines to accommodate these ratio ranges 1 1 4 1 2 1 8 1 and 5 1 to 20 1 The linkage must be adjusted for each material application so that the combination linkage and meter cylinder ratio equals the desired material mix ratio by volume The ratio is checked by weight but the machine meters by volume Weight ratios must be known before proceeding If weight ratios are not known they can be calculated using the specific gravity and known volumetric ratio of each component The initial linkage adjustment point can be calculated by inserting known values into the following formula The resulting value is the distance in inches from the center of the fulcrum point to the center of the component B meter cylinder Measure the distance from the grease fitting on top of the fulcrum to the center of the compo nent B cylinder meter rod For reference see the output charts on pages 15 through 17 Ratio Adjustment Calculation Example DR Required mix ratio by desired volume X 1 PR Selected cylinder ratio 1 1 2 1 5 1 LR Linkage ratio LD Linkage distance component B cylinder center line to fulcrum center divided by LR 1 DR PR _ ER Cylinder ratio 1 1 4 1 machine use PR 1 Cylinder ratio 2 1 8 1 mac
53. ff valve T Figures 14 and 15 Fic 14 8 10 11 Set the component B tank air regulator U to approximately 40 psi 276 kPa 2 8 bar Check to ensure the air valve E to booster pump is turned off and material supply ball valve KK is closed Set feed pump regulator F on proportioner assem bly to approximately 40 psi 276 kPa 2 8 bar The unit is ready to feed material to proportioner F From air manifold on proportioner module d TI3259Ay FiG 15 309790ZAA 23 Setup Prime with Component B Fill the 8900 Proportioner with 1 Place a waste container under the pump bleed valve Material located behind the displacement pump outlet FIG 16 Using an adjustable wrench open the bleed valve counterclockwise 1 3 1 2 turn 1 Place a material waste container under dispense gun Q and open gun FIG 1 page 10 2 Open the main ball valve A FiG 17 on the propor tioner assembly This air valve supplies air to the proportioner control valving and to the feed pump assemblies All other air shut off valves on the
54. form the steps on page page 24 to set an initial flow rate When the setup is complete adjust flow to the correct rate The diagram in FIG 22 shows the inlet and outlet of the meter cylinders in relation to the direction of rod move ment The material pressure gauges will represent either inlet or outlet pressure depending on the direc tion of the rod Inlet and outlet pressures are critical to establishing meter flow rates and balanced pressures FiG 22 Flow Rate Adjustment Example A 20 1 fluid air supply pump ratio with an air regulator setting at 100 psi 7 MPa 7 bar The pump generates approximately 2000 psi 14 MPa 140 bar Fluid pres sure normal friction losses with mastic materials will use 5 15 of the force resulting in actual stall pressure of 1700 1900 psi 18 MPa 130 bar 309790ZAA A B Pump Relationship As a rule of thumb the pressures of the two components should be adjusted to as close to equal as possible under dynamic pressure Adjust the A and B feed pres sures to accomplish this Differences on material viscos ity flow rates hose diameter and length dispense valve and mixer size cause this setting to vary from applica tion to application 1 Adjust the component A air regulator O for desired flow rate FIG 24 2 Adjust the component B air regulator F to balance the A and B regulators Solvent flush Mixed Material for units using mix manifold gun kits 1 Close the comp
55. ght within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la 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
56. hine use PR 2 Oylinder ratio 5 1 20 1 machine use PR 5 Example Desired volumetric mix ratio DR 10 1 Measured distance from grease fitting on top of the fulcrum to the center of the component B cylinder meter rod 14 85 in DR _ 10 PR LR 5 2 1 measured distance 14 85 in s LD LR 1 D 514 OrLD 4 95 in 309790ZAA Operation Verify the Ratio 1 Relieve pressure See Pressure Relief Procedure on page 27 2 Remove gun and place a waste container under the component A and component B hoses 3 Open air valve to turn on unit 4 Activate the unit and using a collection container of known weight collect a cup of component A and a proportionate amount of component B 5 Weigh each component carefully and subtract the weight of the container 6 Convert the manufacturer s ratio to parts component B per 100 parts Component A by weight 2 1 100 50 7 Divide component B weight by component A weight 8 Multiply the result of step 7 by 100 The product is the number of parts of component B the machine dispenses per 100 parts of Component A 9 Compare ratio obtained to ratio desired Always make several ratio checks to ensure accuracy at final setup Any air in the system will cause inaccu rate ratio checks If ratio checks are not consistent review setup procedure 10 If the ratio is incorrect loosen fulcrum screw A and turn the ratio adjustment screw nut B clockwise to decreas
57. id exits the gun The pressure drop is a measure of friction loss caused by hoses the 8900 Proportioner fittings mixers and gun 36 The difference in the gauge reading between the stall condition and running is the amount of dynamic friction loss from the pump assembly plus the flow induced pressure drop from the pump lower to the pressure gauge Viscosity temperature flow rate and gun setup can affect the amount of gauge drop when the trigger is pulled On a typical manual gun system the gauge drops 100 400 psi 0 7 2 8 MPa 7 28 bar Component B Pump Outlet Gauge The component B pump gauge shows line pressure but the component B outlet pressure is generated primarily as a reaction to component A pressure at the mix cham ber For materials running at greater than 1 1 ratio compo nent B cannot open the check injector valve until its pressure equals the component A pressure at the check valve Hoses and injector restriction are chosen to natu rally balance the pressure drop while running and match the component B pressure in the line when stalled Changeovers When the pumps change direction there is a momentary change in gauges In general the gauges will drop 5 1596 then return However many factors affect the actual fluctuation such as pump selection fluid charac teristics flow rate temperature and length of hoses Check valves near the pump outlets isolate the hoses to let them serve as momentary su
58. ificantly longer for air to fill the air motor To check for this observe the gauge on the air motor pres sure regulator during both changeovers e Atthe end of each stroke the air pressure will drop abnormally as the air motor begins to fill e Atthe same time the A and B pump outlet pressures will drop abnormally due to the feed pump s respec tive air motor s reduced pressure e The decrease in the pump outlet pressures causes the flow rate at the dispense gun to be reduced e Once the air motor has filled with air all air pres sures and flow rates will return to normal until the end of the next stroke e The decreased pump outlet pressure may affect the feed pumps checking action and thus mix ratio resulting in the dispense of what appears to be poorly mixed material Changing air pressure changes the compression of the component A hose and material This causes an off ratio condition until pressures stabilize Equip ment air supply pressure must always stay above the motor regulator setpoint 309790ZAA 37 Troubleshooting Pump Troubleshooting Overview Pump Cavitation Under normal operation when the feed pump pressures are balanced component A and component B outlet pressures are consistent Some up or down adjustments in feed pressures will be necessary to keep the pumps outlet pressures bal anced This is due to viscosity differences in the two materials volumetric ratio and required flow rate B
59. ion Disposable Mixer System 1 c BR D Remove and discard the mixer Trigger gun to ensure the outlet is clear Turn off the main air valve Wiper off gun nose If material is moisture sensitive or dries out protect the outlet with the night cap and ISO pump oil General Ratio Check Procedure Checking the ratio allows the user to take samples of the metered material to ensure the equipment is operating properly The unit meters by volume but it is more conve nient to check the ratio by weight You must know the ratio by weight or the specific gravity of the materials to convert volumetric ratio to weight ratio Remove the hoses from the dispense gun Take a material sample from the outlet of these hoses Open the air ball valves push up and collect a large material sample approximately 1 pint of com ponent A in separate containers of known weight Material flowing from each hose provides a sample for ratio check When sample is collected turn off air supply ball valve Weigh the component A and component B samples and subtract the weight of the collection containers Convert the material manufacturer s ratio to parts component B per 100 parts component A by weight For example a 2 1 ratio component A component B becomes 100 50 Divide component B sample weight by component A sample weight Multiply the result of previous step by 100 The product is the parts component B dispensed by the m
60. jection Hazard Spray from the gun hose leaks or ruptured components can inject fluid through skin and cause extremely serious injury including need for amputation Fluid splashed in the eyes or on skin can cause A serious injury e Fluid injected into skin might look like just a cut but it is a serious injury Get immediate surgical treatment e Do not point the gun at anyone or any part of the body e Do not put hand or fingers over the spray tip nozzle e Donot stop or deflect leaks with hand body glove or rag e Do not blow back fluid this is not an air spray system e Always have tip guard and trigger guard on the gun when spraying e Check gun diffuser weekly Refer to gun manual e Check trigger safety operation before spraying Lock trigger safety when you stop spraying e Follow the Pressure Relief Procedure page 27 if the spray tip nozzle clogs and before cleaning checking or servicing the equipment e Tighten fluid connections before operating equipment Check hoses tubes and couplings daily Replace worn or damaged parts immediately Do not repair high pressure couplings replace the entire hose e Fluid hoses must have spring guards on both ends to help protect them from rupture caused by kinks or bends near the couplings Toxic Fluid Hazard Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on skin swal lowed or inhaled e e Know specific hazards of the
61. lly stir it with a metal or plastic rod until it is mixed Do not use wood to stir as it can splinter and contaminate the material Do not mix air into the material Set the pail on the ram base Slide it back toward the ram tube and supports and center it under the wiper plate To prevent air from being trapped under the wiper plate scoop fluid from the center of the pail to the sides to make the surface concave 309790ZAA Setup A WARNING vt When operating the pump or raising or lowering the ram keep hands away from the wiper plate fluid con tainer lip and pump intake Read warnings page 5 7 10 11 12 With hands away from the pail and wiper plate set the ram lever C to NEUTRAL horizontal position Let the ram lower until the wiper plate rests on the pail lip Ensure the pail is aligned with the wiper plate Push the ram directional lever C DOWN and increase ram air pressure until plate completely engages into the pail Slowly unscrew the vent stick until you hear air escaping When air is evacuated set the ram lever C to NEUTRAL and lower ram pressure to 20 30 psi 138 207 kPa 1 4 2 1 bar Unscrew the vent stick and put the ram lever M in the DOWN position keeping the vent stick over the vent port Slowly increase down pressure until material seeps from vent port the quickly refasten vent stick 21 22 Setup
62. ls 6 Open the material container Remove any packing materials and inspect for material contamination If the container has a plastic liner pull it tightly over the sides of the container and secure the liner in place with tape wrapped below the top drum rim 7 Position the drum so it rests evenly between the centering guides and is fully backed into the stops located near the back of the ram base plate 8 Open the drum vent valve W FIG 9 309790ZAA Setup FIG 9 A WARNING WA When lowering the ram keep hands and body away from the ram plate and material drum Read warnings page 5 9 With hands away from the pail and wiper plate N set the ram lever P FiG 10 to NEUTRAL horizon tal position Let the ram lower until the wiper plate rests on the pail lip 10 Lower the ram plate into the drum move ram lever to DOWN position CAUTION Do not lower ram if a drum is not in place Doing so can damage drum centering guides Ram Separation Air Button Fic 10 11 After the ram plate seals contact the drum adjust the ram air regulator R to about 30 50 psi 207 345 kPa 2 1 3 4 bar 12 When the ram stops and material fills the bleed port or air stops bleeding out close the drum vent valve W FiG 9 13 Supply unit is now ready to fill lines to proportioner 19 Setup Prime Pump A 2 Slowly open the component A air motor shutoff valve G Fic 7
63. lve 303 pull out valve 304 and replace with new valve Reassemble in reverse order of disassembly Make sure not to remove spacer 305 during disassem bly This spacer sets correct alignment of valves Reattach air valve assembly to the 8900 cylinder Eo 32 block and connecting rod assembly 303 304 305 D T H Re 1 Li in TH FIG 33 309790ZAA 45 Disassemble Fluid Valve Disassemble Fluid Valve Pull off end cap 413 Pull out ball passage 411 with backup ring 409 packing o ring 410 and bushing 408 6 Remove packing assemblies consisting of seal 402 o ring 403 bushing 404 o rings 406 407 and connector 405 7 4 way valve must be installed so that flow paths marked on shaft see illustration below are 90 out of phase with each other Stamped indicators on shaft end of valves show material flow paths The 8900 Proportioner will not cycle if the valves are not Close air valve 2 Remove valve assembly from 8900 cylinder Take EN When reassembling apply grease to all o rings and off hose 17 union 9 fitting in 5 fitting out 5 bearings See FIG 31 3 Remove 4 socket head cap screws 415 FIG 35 404 Fic 35 46 309790ZAA Disassemble Fluid Valve 309790ZAA 47 P
64. m id red SLEEVE protective NIPPLE short 1 4 18 npt VALVE injector 40 1 4 npt SWIVEL union FITTING adapter swivel ti16738a 1 2 1 4 60 25 2 1 1 1 309790ZAA MD2 20 ft Hand Gun Wide Ratio Module No 24H260 Close Ratio Module No 24H261 Ref No Part No Description Qty 1 255445 VALVE MD2 10 1 hard seats 1 gun air 24H260 255442 VALVE MD2 1 1 hard seats gun 1 air 24H261 15K688 NUT retainer ratio check LC0080 MIXER static 3 8 x 36 122969 FITTING elbow 1 4 npt x SAE 06 9 16 18 thread 501867 VALVE check 205324 HOSE coupled 61120 1 ft H52525 HOSE fluid nylon 1 4 in 6 4 mm ID 1 4 npsm fbe 25 ft 7 6 m long oN OD O1 CO ND O1 D D Parts Ref No Part No Description Qty 9 157350 ADAPTER 3 8 npt x 1 4 npt 1 10 207946 SWIVEL straight 1 11 H45010 HOSE coupled 1 2 in 13mm ID 2 1 2 14 npsm 50 ft 15 2 m long 12 158491 FITTING nipple 3 13 617467 BUSHING hex reducing 3 4 x 12 1 14 160327 UNION adapter 90 2 15 503536 FITTING nipple reducing mod 1 16 598140 FITTING elbow 5 32t x 1 8 in 2 npt m 17 514607 TUBE nylon 2 5mm id red 30 18 552071 SLEEVE protective 25 19 189018 SWIVEL 5800 psi 2 309790ZAA 16 ti16739a 77 Parts MD2 15 ft Hand Gun Wide Ratio Moisture Lock Module No 24H243 Ref Ref No Part No Description Qty No Part No Description Qty 1 255445 VALVE MD2 10 1 hard seats 1 12 156172 FITTING u
65. materials have a tendency to cure slowly on the walls of the mixing chamber Experience will dic tate how often the mixer or mixer elements should be thoroughly cleaned or replaced O rings Seals O rings and seals will be damaged if soaked in solvents When reusing wipe with solvent and dry immediately 309790ZAA Service and Repair Repair the Cylinder Fixed Ratio EN e Relieve pressure throughout the 8900 Propor tioner assembly Follow the pressure relief procedure on page 31 Reference numbers shown in parentheses in Service and Repair procedures refer to refer ences in figures and parts lists FiG 29 Fixed Ratio 8900 1 Disconnect hose 17 on cylinder end manifold FIG 29 2 Remove guard tube 116 3 Loosen and remove 4 locknuts 30 4 Loosen nut 10 on coupling 11 and disconnect pump rod from coupling EN If the entire cylinder needs to be removed and ser viced at another location loosen and remove screws 49 Then loosen union 9 to remove the cylinder assembly from unit See page 49 5 Pull on cylinder block 113 Fic 31 Cylinder should come apart 6 Remove rod and piston assembly from cylinder 7 Remove packing nut 115 from cylinder block 113 and remove throat packings and glands 110 111 112 309790ZAA Service and Repair 8 Remove packing nut 103 from opposite cylinder end cap 106 and remove throat packings and glands 110 111 112 9 Remove pisto
66. mp 3 4 npsm f Component B Pump 3 4 npsm f 8900 Proportioner inlet size Component A Pump 3 4 npsm f Component B Pump 3 4 npsm f 8900 Proportioner wetted parts Carbon steel stainless steel zinc black oxide PTFE fluoroelastomer electroless nickel aluminum nylon Refer to pump Output Charts on pages 15 17 for ratio adjustment and displacement pump part number information e For additional wetted parts information and technical data refer to your separate component manuals Accessories 570264 President 10 1 mounted on a 5 gallon 19 liter pail Used for solvent flush of mix kit assembly Repair Kits for A and B Metering Cylinders Cup Ratio Size Meter Repair Kit Order 2 Cylinder Ratio Kit 1000 C24166 or 289402 C05032 C23136 C23041 500 C24166 or 289402 C23350 C23200 C23087 250 C24166 or 289402 C23318 C23171 C23067 111 C24166 or 289402 15C181 15C180 100 C24166 or 289402 C22282 C23137 C23042 Cylinder Repair Kits Cross Reference 289402 Repair Kit C24166 EDPM 8900 Cylinder Repair Kit Qty Description 15R212 188554 2 PACKING o ring 15R213 C20278 2 PACKING o ring C21002 C21002 10 PACKING vee C36244 C36244 2 GLAND male C36246 C36246 2 GLAND female 84 309790ZAA Technical Data Repair Kits for All Proportioners For Part Number Repair Kit Replacement Parts Actuator 16E287 C24047 4 Way Valve 3 16 in C
67. n assembly 106 107 from rods 101 102 10 Replace V packings and glands on both ends with new ones and reassemble in reverse order of disas sembly 11 Replace cylinder end o rings 109 on each cylinder end cap Apply grease to each to help hold o ring into end cap 12 Push piston assembly through cylinder block 113 EN Use grease generously during reassembly 13 Replace o rings 114 on each packing nut and Screw then screw packing nut back into cylinder end caps Hand tighten until firmly seated on pack ings then wrench tighten 1 4 turn 14 Push cylinder assembly back together 15 Complete reassembly of the cylinder in reverse order of disassembly Use threadlocker 118 when reassembling rods 101 102 Torque to 55 ft Ibs 74 25 Nem Fic 30 Variable Ratio 8900 43 Service and Repair A WARNING w PROPORTION 30 D 10 TI2761A 104 109 114 101 116 ie was 77 2 WA oc 103 112 110 111 102 107 106 113 118 inn FIG 31 44 309790ZAA Replace Air Valve Service and Repair Unscrew 2 socket head cap screws 311 FIG 33 Pull complete air valve assembly off cylinder and connecting rod assembly Remove retaining ring and plate off end and pull rod through Remove retaining ring off appropriate air va
68. ner system include the tri core mixer flexible hose mixer or disposable mixer Ratio Checks On the variable ratio model a ratio check station option verifies the volumetric mix ratio of the two components It is located at the outlet blocks With all outbound fluid valves closed each component flows through individual ball valves opened by a common handle into containers Volumetric mix ratio can be calculated from the weight of each component or by direct measurement Ratio checks are performed with the back pressures set to actual operating pressures to simulate the normal back pressures created by the mix chamber and gun Dispense Valve An extrusion flow gun is commonly used as the applica tion device It has a final or clean up mixer installed in the handle Various extrusion nozzles are available for caulking or sealing applications 309790ZAA Theory of Operation Some 8900 Proportioners use a 2K disposable mixer element dispense valve instead of the flow gun The 8900 Proportioner can be used in automatic assembly lines with the addition of a logic interface Models Models K Refer to form 684041 for selection information 890 D Power Valved Passive Proportioner Code A Proportioner Selection A Cyl B Cyl Module Number 1 1 1 Fixed 1000 1000 570371 2 2 1 Fixed 1000 500 570372 3 2 5 1 Fixed 250 100 570373
69. ng can be accomplished 309790ZAA 35 Troubleshooting Troubleshooting 8900 Proportioner Operating Pressures There are four fluid pressure gauges on a typical 8900 Proportioner system They are mounted on Component A inlet block Component B inlet block Component A outlet block Component B outlet block What the fluid gauges tell you Inlet Gauge The pump A and pump B inlet pressure gauge shows whether there is sufficient material supply to reliably feed each metering pump during its intake stroke These double acting pumps dispense and load fluid on both strokes The pump A and pump B supply air pressure should be set high enough to maintain reliable pump feed pres sures but no higher than necessary If gauge pressure is not consistently steady increase fluid pressure Outlet Gauge The pump A and pump B outlet gauge displays one of two conditions stalled and running e Stalled With the pump air valve on and the gun closed the gauge will show full stall pressure This pressure is the fluid to air pressure ratio of the pump assembly times the air pressure from the main reg ulator minus the friction loss of the motor and pump assembly The fluid to air pressure ratio changes with different motors different supply pumps and different ratio settings e Running When running the gauge reads the flow induced pressure drop between the gauge and the gun outlet The motor power is used up by the time the flu
70. nion swivel 1 gun air 13 214925 SWIVEL hose 2 2 189018 SWIVEL 5800 psi 1 14 160327 UNION adapter 90 1 4 162453 NIPPLE 1 4 nps m x 1 4 npt 4 15 503536 FITTING nipple reducing mod 2 5 122969 FITTING elbow 1 4 npt x SAE 06 2 16 598140 FITTING elbow 5 32t x 1 8 in 32 9 16 18 thread npt m 6 501684 VALVE check 1 17 514607 TUBE nylon 2 5mm id red 15 7 235905 HOSE coupled 2 5 ft 1 18 552071 SLEEVE protective 1 8 514428 HOSE 1 4 in PTFE x 10 ft 2 19 LC0057 MIXER shroud 1 4 24 1 9 162024 COUPLING 1 20 155570 UNION swivel 1 10 161490 COUPLING reducing 1 21 947937 VALVE injector 40 1 4 in not 1 11 512247 HOSE 5 8 PTFE 7 5 ft 3 4 npt m 2 22 100730 BUSHING 1 ti16737a 78 309790ZAA High Volume Static Mix Manifold Module No 570391 Ref No Part No Description Qty 157785 UNION swivel 512151 VALVE ball 175013 NIPPLE pipe 235497 VALVE check 160327 UNION adapter 90 100615 BUSHING hex steel O O1 BR ND DN 8 D D SSNNN 12 b 309790ZAA Ref No 10 11 Part No 501392 100896 156823 214037 204938 Parts Description Qty FITTING cross 3 4 in npt cs 2000 1 psi FITTING bushing pipe UNION swivel VALVE ball HOSE coupled 61120 25 ft 7 TI3261A 79 Parts High Volume Static Mix Kit with Pump Pilots Module No 570263 Ref No Part No Descrip
71. njector on hand A fouled injector can then be replaced quickly and thor oughly cleaned and held for future use 42 Preventive Maintenance 1 A Air supply Oil level in main air line lubricator should be checked daily and refilled when necessary with SAE 10W non detergent oil Adjust to dispense 1 drop per minute during operation Main air line filter should be drained as required Excessive amounts of water in the system will reduce machine performance Housekeeping Spilled materials on any part of the equipment should be cleaned up promptly Your sys tem is precision equipment and should be main tained as such A light coating of petroleum jelly on components will often prevent spilled material from sticking to equipment Pumps Pump packing should be tightened daily the first week of operation and weekly thereafter When using Throat Seal Lubricant TSL or ISO oil the lubricant should be maintained at an adequate level in the pump packing reservoir These lubri cants prevent material from sticking to pump rods extends packing life and protects material from con tamination from the atmosphere Use ISO oil when dispensing moisture sensitive materials Meter Maintain TSL or ISO oil in reservoir if used grease zerk fitting Clean up spills as soon as possi ble to prevent damage to the meter Mixer With most materials frequent use of equip ment is all that is needed to prevent internal curing Some
72. o 570369 C23547 RING backup 570366 only Models 570371 and 570376 only C23515 RING backup 570369 only Part No C24145 C23574 RING backup 570367 only Models 570371 570372 570374 246557 and 570376 109 C20278 O RING fluoroelastomer 2 Ref 110 C21002 V PACKING PTFE 10 el 111 C36244 GLAND male 2 No Part No Description Qty 112 C36246 GLAND female 2 101 C24054 SHAFT piston outer 1 113 C24023 BLOCK cylinder outside 1 102 C24055 SHAFT piston inner 1 114 188554 O RING fluoroelastomer 2 103 C24022 NUT packing 1 115 C57617 NUT packing 1 104 C24026 BLOCK cylinder inside 1 116 C57618 TUBE guard 1 105 15C180 CYLINDER 111 246558 only 1 117 179788 LABEL warning 1 C23171 CYLINDER 250 570366 only 118 SEALANT thread lock 1 C23200 CYLINDER 500 570367 only C23137 CYLINDER 100 570369 only EPDM replacement part available in kit 289402 C23136 CYLINDER 1000 C24145 only 114 104 109 105 118 111 110 112 114 101 Im es Et f ed 103 112 110 111 102 108 52 NN 2 i 107 106 a E AR Ne A LEP AS 109 11 117 116 gt C24145 NS NOR NO RO OA A NE MA NaN 108 107 106 309790ZAA Limit Valve Ref No 301 302 303 304 305 306 307 Ref No ref no 26 FR 38 VR 308 309 Part No C24014 310 311 312 Part No Descripti Q 313 ption ty 314 C20439 RING retaining ext 4 315 C24008 WASHER 2 416 C20407 RING retainer 2 317
73. onent A and component B valves on the mix chamber assembly See FIG 23 2 Ensure solvent valve is closed 3 Set solvent flush pump air regulator to approxi mately 25 psi 172 kPa 1 7 bar and open the air valve 4 Openthe solvent supply valve ensuring that the dis pense valve touches a grounded metal waste con tainer and purge until solvent comes out clean 5 Close solvent supply valve Component B Valve _ li Le EL De rar TI3261A Component A Valve Solvent Valve Fic 23 309790ZAA Operation 8900 Proportioner with Disposable Mixer Gun 1 Load the material See page 19 2 Setratio For variable ratio models see page 14 3 Install the mixer on the gun 4 Open the pump A and pump B air shutoff valve S FiG 24 FIG 24 5 Trigger the gun to dispense mixed material Adjust the component A air regulator O for the desired flow rate 7 Adjust the component B supply air regulator F so that component B pressure is approximately equal to the component A pressure 8 When you have finished dispensing remove and dispose of the mixer and install a red plastic cap part no 551327 29 Operation Changing Component A Drum When the ram plate is extended fully to the bottom of the drum and the pump begins to cavitate you need to change
74. ot 70 205324 HOSE coupled 61120 1 ft 35 C26088 VALVE cone extension 164672 ADAPTER 36 C26086 STOP cone assembly 73 159239 FITTING nipple pipe reducing 37 103374 SCREW machine rdh 74 552208 VALVE ball 3 way 38 105192 SCREW cap hex head 75 100206 BUSHING pipe 40 C24017 ROD trip valve 76 552205 MIXER pipe sst 1 4 4 2 in 12 el 41 C20068 PIN spring 77 626760 MANIFOLD ratio check 8900 shot 42 C24018 COLLAR stop 79 102646 VALVE ball 43 C24020 COLLAR clamp 80 156877 NIPPLE long 44 120753 FITTING elbow male 90 81 112013 NOZZLE needle 45 513066 TUBE 3 8 ft OD nylon 82 112014 NOZZLE needle 46 C12509 TUBE nylon 83 112015 NOZZLE needle 84 112020 NOZZLE needle 85 112021 NOZZLE needle 86 112022 NOZZLE needle 87 162449 FITTING nipple reducing 88 100403 PLUG pipe 90 158491 FITTING nipple PB D ND 2 DO GP ND ND NNR N N DDR s D D D D ND D D ND ND ND HH 70 309790ZAA 18 13 121712 15 16 10 11 B 47 2 axis V1 front V2 rear 27 __34 JL oss fan n 5 y a 67 3 p 67 y 68 81 82 83 69 84 85 86 O Q 44 54 9 53 T Rs e 54 ui Detail C 46 46 46 To bottom front 60 47 5g N ue 59 52 47 a 52 IN A 60 44 S 96 46 SL el 2 ef wy 47 48 46 See Det
75. products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 309790 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2003 Graco Inc is registered to ISO 9001 WWW graco com Revised 07 2011
76. rer s recommenda tions Spray gun dispense valve ground through connection to a properly grounded fluid hose and pump Fluid supply container follow your local code Substrate follow your local code Solvent pails used when flushing follow your local code Use only conductive metal pails placed on a grounded surface Do not place the pail on a noncon ductive surface such as paper or cardboard which interrupts grounding continuity To maintain grounding continuity when flushing or relieving pressure hold a metal part of the gun dis pense valve firmly to the side of a grounded metal pail then trigger the gun valve 309790ZAA Installation Flush 2 Flush the system and all hoses by very slowly open ing the motor control valves until 30 psi 207 kPa 2 1 bar is shown on the component A outlet pres A WARNING sure gauge Me Flush for 1 2 minutes then close the motor control valves Read warnings pages 4 5 Follow Ground instruc tions page 12 e The equipment was tested with light soluble oil A CAUTION Flush the system before loading material to avoid To avoid damaging the pump open the motor control contamination valves very slowly to prevent a pump runaway condition e Flush at the lowest pressure possible and check connectors for leaks It is normal for the air valve to exhaust air when it is partially open To flush the system 3 Check connectors for leaks and tighten th
77. rge chambers This is why flow from the gun is smooth during changeover Abnormal Readings Since so many factors affect gauge readings it is impor tant to know what is normal Note how your gauges read when the machine is setup and running a good mix with no soft spots What are the stall pressures and what are the running pressures for a given inbound air pressure How much drop is there on changeover If something goes wrong a change on the gauges can indicate what the problem is Note those changes and work through the troubleshooting guide beginning on page 39 309790ZAA Air Supply Troubleshooting Chart Troubleshooting Problem Cause Solution Abnormal pressure loss on air motor pressure regulator gauge during both changeovers Air line restriction due to quick dis connect pin fitting Remove quick disconnect from the air line and replace it with bleed type air shutoff valve Abnormal A and B pump outlet pres sure loss during both changeovers Air supply line ID to each feed pump is too small Replace with minimum 3 4 in 19 mm ID hose Reduced flow rate Undersized air compressor Replace with properly sized air com pressor Off ratio material During normal operating conditions the feed pump A and B air motors are filled with air almost instanta neously on both changeovers However if the feed pump air supply is restricted it can take sign
78. swivel 90 1 55 113208 FITTING tube 2 27 113269 VALVE ball vented 500 1 58 190256 CLAMP support 2 28 155865 UNION adapter 1 59 100680 SCREW cap hex head 4 29 237569 WIRE assy 25 ft 1 60 101566 NUT lock 4 34 156971 NIPPLE short 1 61 159239 FITTING nipple pipe reducing 1 35 104984 TEE pipe 1 62 100023 WASHER flat 4 36 113286 VALVE safety 1 64 114320 FITTING connector 1 8 npt f 1 37 160701 ELBOW street 1 65 115901 TRIM edge protection 2 41 238925 PISTON ram 5 gallon 1 66 100896 FITTING bushing pipe 3 42 237562 SUPPORT pump 1 67 160327 UNION adapter 90 2 43 160107 NUT cap 1 68 235497 VALVE check 1 44 101533 WASHER spring lock 1 69 H45010 HOSE fluid nylon 1 2 in 13 mm 1 45 190265 SPACER 1 ID 1 2 npsm fbe 10 ft 3 05 m MS E coU dol 70 214656 HOSE coupled 61209 10 ft 1 49 110319 GAUGE pressure air 1 8 in npt 1 74 109126 HOSE coupled 10 ft 73 158491 FITTING nipple 2 60 309790ZAA Parts o o GO iD o 61 309790ZAA Parts 20 1 President on 55 Gallon Ram See Graco Manuals 306934 and 308027 Module No 570114 Ref No Part No 1 215335 2 222768 3 276025 5 206537 7 184140 9 237569 10 104984 11 113286 12 156971 16 102637 18 100101 19 100122 20 100133 22 100672 23 100132 24 100464 25 101533 26 101535 28 189559 29 160701 31 157416 32 158979 36 110319 37 155541 38 110318 62 Description BASE ram PUMP President 4 5 cm
79. tation the interruption in the B pump material output may cause component A rich material to dispense which may appear as poorly mixed mate rial 38 Pump Failure to Seal Under normal operation the output of the component A and component B pumps depends upon proper sealing of their internal packings If packings fail to seal properly the pump material out put and thus the output pressure is reduced Depend ing on the location of the failure the pressure reduction may occur on the pump upstroke downstroke or both strokes Component B Pressure Relief Valve The proportioner includes a spring loaded overpres sure relief valve which bypasses component B back to the supply when pressures exceed 3400 psi 23 MPa 234 bar 309790ZAA Troubleshooting Guide Feed pumps Troubleshooting Problem Cause Solution Erratic feed pump speed Pump cavitation Bleed air from pump Pumping too fast Turn down air pressure regulator Improper pump loading Increase ram down pressure Ram valve not in down position Pump lower not performing Rebuild pump Material leaking from top of pump Loose packing nut Retighten Worn throat seals Rebuild pump replace seals Feed pump fails to cycle Air supply off Check air valves line pressure Turn on if required Air pressure too low Stalled air motor Increase air pressure on respective feed pump air r
80. the material or trapped in the pumping and metering components Bleed the air from the pump 309790ZAA Troubleshooting Guide Manifold Mixer Troubleshooting Problem Cause Solution Poor mix quality Dirty mixer Disassemble Tri Core mixer clean housing and end caps and replace mix elements Inadequate mixing Add mixer with more elements or larger ID mixer Dirty mixer and gun Replace flex mixer or clean Tri Core mixer and gun Tri core mixer assembled improperly Reassemble with scribe lines on end caps aligned Fouled or plugged component B injector Clean or replace injector Cavitation due to ram air control valve not in DOWN position Cavitation due to low ram pressure Place control valve in DOWN position Increase to required operating pressure Reduced flow rate Dirty mixer Disassemble Tri Core mixer clean housing and end caps and replace mix elements Dirty mixer and gun Replace flex mixer or clean Tri core mixer and gun Leaking component B shutoff valve Repair or replace valve Poor purge quality Leaking component B shutoff valve Repair or replace valve May require solvent flush after valve replacement Abnormally high B pump outlet pres sures Fouled or plugged component B injector Feed pressure too high Clean or replace injector Reduce feed pressure Abnormally high pump A o
81. ther feed systems may be used to supply A and B materials to the 8900 Proportioner Generally these feed systems are provided by others and are not addressed in this manual This manual applies only to the Graco Configured 8900 Proportioner system 309790ZAA Pump Fluids to the Mixer Fluid is pumped through the proportioner to a mix cham ber or to a 2 component dispense gun where compo nent and component B are first introduced before being mixed with a static mixer A fluid injector nozzle check valve injects component B into component at the mix chamber When enough pressure builds up the check valve opens and compo nent B flows into the mix chamber This means that dur ing flow conditions with two positive displacement cylinders linked together the pressures at the mix point are equal Any pressure differences noted on the gauges while running reflect differences in the pressure lost by each fluid getting from the gauge to the mix point These pressure drops are caused by hoses and fittings in con junction with material viscosity Mix the Fluids Both components leave the mix chamber and enter a static mixer where they are mixed to a homogeneous blend The mixer consists of a series of left and right hand spiral elements This is true for both mix chamber and 2 component mix gun When the components are pumped through the mixer they are progressively divided and recombined Static mixers used on the 8900 Proportio
82. tion 1 504704 FITTING nipple hex 2 512152 VALVE ball 2000 psi 1 in npt f 3 514058 MIXER pipe 1 in x 12 4 158383 FITTING union adapter straight 5 500946 HOSE 1 in mbe 6 502766 FITTING cross 1 in npt f sst 7 160327 UNION adapter 90 8 175013 NIPPLE pipe 9 235497 VALVE check 10 157785 UNION swivel 11 100615 BUSHING hex steel 12 156823 UNION swivel 13 214037 VALVE ball 14 204938 HOSE coupled 61120 25 ft 33 10 328987 15 6 14 34 11 i 15 80 12 7 33 10 32 8 9 8 13 9 1 NERO T 16 18 26 Ref No 15 16 18 20 21 22 23 26 27 28 30 32 33 34 28 28 Part No 158586 597151 C12509 104632 512912 158491 C20344 104631 522071 C19391 100474 512151 215238 241358 Description FITTING bushing FITTING elbow TUBE nylon VALVE piloted MUFFLER polyethylene 1 2 npt FITTING nipple FITTING tee 1 8 brass VALVE foot SLEEVE protective 2 1 ft FITTING elbow 1 4 npt x 1 4 od tube COUPLING pipe VALVE ball HOSE coupled 61220 KIT accessory a 16 18 23 17 18 16 20 21 18 WA 21 Is 22 mY N 22 20 18 309790ZAA Stanchion Module No 570071 Ref No Part No Description 167636 BASE ram 167639 BRACKET cylinder 176629 CYLINDER ram 166552 CAP cylinder RON Qty 30979
83. utlet pres sures Restriction in gun or hose plugged check valve Clean out gun Inspect for cured material in check valve Soft spots or color change relating to changeovers Pressures are out of balance Adjust pressure settings on A and B supply pumps to balance outbound ram pressure too low on feed pump 309790ZAA 41 Troubleshooting Component B Injector In most dispense systems an injector is included in the component B fluid line This injector adds back pressure to the system and provides the necessary pressure bal ance between component A and component B to achieve the proper ratio and mix If the injector becomes fouled with mixed material the pressure indicated on the B pump outlet gauge will increase and upset the pressure balance resulting in the dispense of poorly mixed material If the injector becomes completely plugged only compo nent A is dispensed from the gun and the B pump outlet pressure will increase until the relief valve discharges If the injector valve sticks it can react sluggishly causing Soft spots after valve triggering or changeover Keep the injector clean Inspect the housing tip and nee dle end for dents or scratches Lapping the needle to the housing with automotive lapping compound will recondi tion the seat needle When reassembling the injector tighten the nut 2 2 5 turns after the slack is taken up It is good practice to have a clean i

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