Graco Foam-Cat Series Operation manual

05217B

Instructions — Parts List

1:1 RATIO, 210 LITER (55 GAL.) SIZE

Foam-Cat® Feed Pump

For use in drums of polyurethane chemicals.

180 psi (1.2 MPa, 12.4 bar) Maximum Air Working Pressure

180 psi (1.2 MPa, 12.4 bar) Maximum Material Working Pressure

*Model No. 226946, Series B

Includes airtight bung adapter

Feed Pump Kit 217381

Includes two Model 226946 Feed Pumps, air dryer,

and air and fluid hoses.

II 1/2 G T6

ITSO3ATEX11227

2575

307552K

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

Read warnings and instructions. See

page 2 for Table of Contents.

2 307552

Table of Contents

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . 16

Symbols

Warning Symbol

Caution Symbol

WARNING

This symbol alerts you to the possibility of serious

injury or death if you do not follow the instructions.

CAUTION

This symbol alerts you to the possibility of damage to

or destruction of equipment if you do not follow the

instructions.

WARNING

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

•This equipment is for professional use only.

•Read all instruction manuals, tags, and labels before operating the equipment.

•Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

•Do not alter or modify this equipment.

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

•Do not exceed the maximum working pressure of the lowest rated component in your system. This equipment

has a 180 psi (1.2 MPa, 12.4 bar) maximum working pressure at 180 psi (1.2 MPa, 12.4 bar) maximum

incoming air pressure.

•Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data

section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

•Do not use hoses to pull equipment.

•Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses

to temperatures above 82°C (180°F) or below –40°C (–40°F).

•Securely mount the pump. Do not attempt to operate it while holding it.

•Do not lift pressurized equipment.

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

•Graco Inc. does not manufacture or supply any of the reactive chemical materials that may be used in this

equipment and is not responsible for their effects. Because of the vast number of chemicals that could be used

and their varying chemical reactions, before using this equipment, the buyer and the user should determine all

facts relating to the materials used, including any of the potential hazards involved. Particular inquiry and

investigation should be made into potential dangers relating to toxic fumes, fires, explosions, reaction times, and

exposure of human beings to the individual components or their resultant mixtures. Graco assumes no

responsibility for loss, damage, expense or claims for bodily injury or property damage, direct or consequential,

arising from the use of such chemical components.

INSTRUCTIONS

307552 3

WARNING

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,

inhaled, or swallowed.

•Know the specific hazards of the fluid you are using.

•Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and

national guidelines.

•Any additives to the air supply, such as oil or anti–freeze will be exhausted into the atmosphere.

•Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent

manufacturer.

FIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result

in a fire or explosion and serious injury.

•Ground the equipment. Refer to Grounding on page 5.

•If there is any static sparking or you feel an electric shock while using this equipment, stop pumping

immediately. Do not use the equipment until you identify and correct the problem.

•Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.

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

•Electrically disconnect all equipment in the work area.

•Extinguish all open flames or pilot lights in the work area.

•Do not smoke in the work area.

•Do not turn on or off any light switch in the work area while operating or if fumes are present.

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

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

•Keep clear of all moving parts when starting or operating the pump.

•Before servicing the equipment, follow the Pressure Relief Procedure on page 7 to prevent the equipment

from starting accidentally.

4 307552

Installation

NOTE: The terms ISO and RES used in the text refer to

the polyurethane foam chemicals, Isocyanate and Resin.

NOTE: Reference numbers and letters in parentheses in

the text refer to the figure illustrations and the Parts

Drawing.

Installing the Feed Pumps

1. Screw the bung adapter (40) and pump tightly into the

drum cover. See Fig 1.

2. Tighten the retainer (38) firmly to complete the airtight

seal.

3. Separate the two halves of the identification label (15)

along the perforation. Clean the surface of the air

motor with solvent and apply the appropriate label

(RES or ISO) to identify the type of material being

pumped.

4. Install an air regulator in the feed pump air inlet to

control pump speed. To install, remove the air valve

(8) and use suitable adapters for the regulator and

pin fitting. Use thread sealer on male threads.

WARNING

A bleed–type master air valve (E) is required in your

system, to help reduce the risk of serious injury,

including splashing fluid in the eyes or on the skin, and

injury from moving parts if you are adjusting or repairing

the pump.

The bleed–type master air valve (E) relieves air trapped

between this valve and the pump after the pump is shut

off. Trapped air can cause the pump to cycle

unexpectedly and result in serious injury, including

amputation. Locate the valve close to the pump.

05217B

FIG.1

307552 5

Installation

5. Connect an air supply hose to the 1/4 npt air line

coupler (13). Air supply hoses (103) are supplied in

Kit 217381. See Fig 3, page 6.

6. Connect a fluid supply hose from the 3/4 npt(f) fluid

outlet of the ISO feed pump to the inlet fitting of the

ISO proportioning pump, using adapters as needed.

Then connect a fluid supply hose between the RES

feed pump and RES proportioning pump.

Grounding

Remove the ground screw (Z) and insert through eye of

ring terminal at the end of ground wire (Y). Fasten ground

screw back onto pump and tighten securely. See Fig 2.

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

Order Part No. 222011 Ground Wire and Clamp.

Feed Pump Kit Installation

The following instructions assume you are using this kit

with a Graco Foam–Cat Sprayer.

1. Install the feed pumps as described in Steps 1–4, on

page 4.

2. Mount the Air Dryer (105) in any suitable location.

Refer to manual 307548 for the mounting hole

diagram. See Fig 3.

3. Unscrew the air dryer ring (F) to remove the bowl.

See Fig 3. Remove the filter and fill the bowl with the

desiccant, provided. Reassemble.

4. Install the drum fittings (H) in the 3/4 in. vent port of

the proper drum.

CAUTION

Be sure all hose connections in your polyurethane

foam spray system are clearly labeled ISO or RES

and make connections only with identically labeled

components to avoid material crossing.

Crossing polyurethane materials will cause the

material to harden in the equipment and may

permanently damage it.

WARNING

Static electricity is created by the high velocity flow of

fluid through the pump and hoses. If every part of the

spray system, and all objects in the spray area are not

properly grounded, the static electricity may cause

sparking. Sparks can ignite fumes from solvents and the

fluid being sprayed, dust particles, and other flammable

substances, causing a fire, explosion and serious bodily

injury and property damage.

To reduce the risk of static sparking, use only conductive

air and fluid hoses and be sure your entire system is

properly grounded. Ground the feed pumps as

explained below.

CAUTION

One end of each fluid hose and each drum nipple (G)

of the drum fittings (H) is labeled ISO or RES. Make

only ISO to ISO and RES to RES connections to avoid

material crossing.

TI1052

FIG.2

6 307552

Installation

5. Connect the dry air hoses (M) to the identically

labeled drum fittings using the special pin fitting (J)

and coupler (N). See Fig 3.

6. Attach a bushing (104) to one end of two of the air

supply hoses (103) and attach a bushing to each

end of the third air hose. See the Parts Drawing on

page 13.

7. Connect one air hose between the feed pump and

the 1/2 npt(f) air manifold on the side of the Foam-

Cat sprayer pump stand. Repeat for the other feed

pump.

8. Connect the hose with the two bushings between

the 1/2 npt(f) air inlet of the Air Dryer and a bleed–

type master air valve (E), required. Then connect

the main air supply line to the air valve.

9. Connect the ISO fluid hose between the 3/4 npt(f)

fluid outlet of the ISO feed pump and the 3/4 npt(f)

inlet of the corresponding displacement pump.

Repeat for the RES pumps.

05218

FIG.3

KEY

AAir Line

BAir Line Filter

EBleed-type master valve

FAir Dryer Ring

GNipple

HDrum Air Fittings

JPin Fitting

KBall Valve

LBushing

MAir Hose (Air Dryer)

NSpecial Air Coupler

7Pin Fitting

8Air Control Valve

13 Air Line Coupler

103 Air Hoses (Pump)

104 Bushing

105 Air Dryer

WARNING

The special air line fitting (J) and coupler (N) are

designed to prevent accidentally coupling an

unregulated air supply hose to the container.

Unregulated air can overpressurize the container and

cause it to rupture, resulting in serious bodily injury

and property damage. If the coupler and fitting ever

needs to be replaced use only original Graco parts.

Never substitute a different type of coupler and fitting!

307552 7

Operation

Pressure Relief Procedure

Starting and Operating the Pump

This pump is designed to be used with a Graco Foam-Cat

Sprayer. If you have purchased such a sprayer, complete

warning and operating instructions are contained in the

manual (307541 or 307542) which accompanied the

sprayer. If you have misplaced these manuals, obtain

additional copies by contacting your Graco distributor.

In general operation, when the pump is used for transfer

and supply operations with no dispensing valve, the pump

will run whenever air is supplied.

Normally, the Feed Pump air valve is opened before any

other equipment in the spray system is turned on. This is

so fluid can be supplied to the components immediately.

For shutdown, disconnect the air line coupler (13). See Fig

Never let the pump run when the drum is empty. A dry

pump can quickly accelerate to a high speed and damage

itself. If the pump is running too fast, stop it immediately

and check and refill the material supply, or flush the pump

with a compatible solvent if you stop spraying for the day.

Always prime the entire system with fluid to remove any air

pumped into the system. Refer to Manual 307541 or

307542. Don’t let the material harden in the pump.

Feed Pump Kit

Refer to the operation instructions on page 2 of manual

307548, which was supplied with the Air Dryer, and the

above instructions for operating the Feed Pumps.

Changing Drums

1. Disconnect the hose coupler (N) from the Air Dryer

drum fittings (H). See Fig 3.

2. Leave the ball valve (K) open for a few minutes to

release the air pressure in the drum, then close the

valves.

3. Remove the pump and the drum fittings from the

drum cover and install them in the new drum of

material.

4. Repeat this procedure for the other material.

WARNING

PRESSURIZED EQUIPMENT HAZARD

The system pressure must be manually relieved to

prevent the system from starting or spraying

accidentally. To reduce the risk of an injury from

accidental spray from the gun, splashing fluid, or moving

parts, follow the Pressure Relief Procedure whenever

you:

• are instructed to relieve the pressure,

• have an air supply interruption,

• stop spraying,

• check or service any of the system equipment,

• or install or clean the spray nozzle.

CAUTION

To avoid crossing material when changing drums,

complete the changing of one type of material before

starting the other.

8 307552

Maintenance

Bung Adapter

If the ISO material shows signs of crystallization, and

whenever the pump is removed from the drum, check the o-

ring (39) and gasket (41) for wear or damage, replacing as

needed. Refer to the Parts Drawing.

ISO Pump Packing Protection and

Lubrication

1. Insert the 14.6 oz. cartridge (16) of IPL in a standard

grease gun.

2. At shutdown each day, stop the pump with the rod

(34) in the down position, then lubricate the

packings liberally with IPL through the grease fitting

(36). Proper lubrication prevents pump sticking. See

Fig 4.

3. Wipe off the extra, contaminated IPL from around

the top of the packing nut (28) and displacement rod

(34).

4. Coat the displacement rod with fresh IPL.

Flushing

1. Connect a short hose to the pump outlet.

2. Insert the pump intake into a pail of solvent.

3. Direct the fluid hose into the pail.

Air Lubrication

If the air supply is dry, periodically oil the air motor. For

manual lubrication, turn off the air, put about 15 drops of

lightweight motor oil in the air inlet (7), reconnect the

hose, and turn on the air. See Fig 4.

1. Open the air valve (8) or regulator to start the pump.

Allow the pump to cycle slowly for at least 5

minutes.

2. Stop and disconnect the air hose.

3. Be sure to relieve the fluid pressure.

4. Push up on the intake valve (35) check plate to drain

the lower part of the pump. See Fig 5.

5. Turn the pump over to drain the upper part of the

pump.

Adjusting the Packing Nut

Periodically, check the tightness of the packing nut (28).

It should be tight enough to prevent leakage; no tighter.

See Fig. 4. If the leakage cannot be stopped, change

the packings to prevent exposure to the fluid being

pumped.

CAUTION

Use only IPL (Isocyanate Pump Lube) to lubricate the

packings of the feed pump. Other types of lubricant

are not as effective in preventing packing damage.

CAUTION

Be sure the solvent used is compatible with the

material to be pumped to avoid material

contamination.

WARNING

Follow the Pressure Relief Procedure on page 7

before adjusting the packing nut.

05219B

FIG.4

03765

FIG.5

307552 9

Troubleshooting

Check all possible remedies before disassembling the

pump.

NOTE: Removing the muffler (P, Fig 6) will increase both the pump flow rate and the exhaust noise and will reduce icing.

WARNING

Follow the Pressure Relief Procedure on page 7

before servicing the pump.

PROBLEM CAUSE SOLUTION

Pump fails to operate Material crystallized Clean pump, use IPL more liberally

Dirty or worn air motor parts Clean air motor, repair

Inadequate air supply or restricted

line

Clear line; see TECHNICAL DATA

Insufficient air pressure, closed or

clogged air valves

Check valves; increase pressure

Clogged material hose or valve Clear obstruction

Worn or damaged valves or seals Service pump

Pump operates, but output is low on

both strokes

Clogged material hose or valve Clear obstruction

Exhausted material supply Refill

Worn or damaged valves or seals Service pump

Pump operates, but output is low on

down stroke

Worn or damaged valves or seals Service pump

Intake valve held open Clear valve, service pump

Pump operates, but output is low on

up stroke

Worn or damaged valves or seals Service pump

Piston valve held open Clear valve, service pump

Erratic or accelerated operation Exhausted material supply Refill

Broken air motor compression spring Replace spring

10 307552

Service

Disconnecting the Air Motor

Flush the pump, disconnect the air supply and relieve all

pressures in the system. Remove the pump from its

mounting. Unscrew the tie rod locknuts (3), remove the

screw (5) and barrel (4) set and lift the air motor.

Unscrew the rod (34). See Fig 6.

Reconnecting the Air Motor

Use lithium base grease on the threads of the rod (34).

Insert the muffler (P) as shown. Hand tighten the rod (34)

into the air motor connecting rod. Install the screw and

barrel set (4 and 5). Lubricate the tie rod threads. To

ensure alignment, thread the tie rod locknuts (3) loosely

onto the tie rods, then torque evenly to 11 N•m (8 ft–lb).

See Fig 6.

Intake Valve

Unscrew the intake valve housing (35). Disassemble,

clean and inspect all parts. Replace worn or damaged

parts. See Fig 7.

Piston Valve

Use a strap wrench to grip the cylinder (25) near the

housing (24) and unscrew it from the outlet housing. Pull

the cylinder down, then loosen the lower nut (19).

Unscrew the piston housing (33). Clean and inspect all

parts. Replace worn or damaged parts. Screw the

connecting rod all the way into the piston housing (33).

Tighten the upper nut (19) against the piston housing and

adjust the lower nut (19) to allow the piston disk (29) free

travel of 3.1 mm (0.1235 in.). See Fig 7.

Throat Packings

Remove the cylinder (25). Loosen the packing nut (28).

Pull the displacement rod (34) down and out. Remove

the glands (21,22) and packings (32). Clean and inspect

all parts. Replace worn or damage parts.

Reassemble the pump. Install packings one at a time to

be sure they nest properly. Leave the packing nut (28)

loosen until the displacement rod (34) has been

installed. Then tighten the packing nut firmly to seat the

packings.

NOTE: Insert the displacement rod from the top of the

outlet housing (24) to prevent packing damage.

Back the packing nut off until it no longer contacts the

packings, then turn it in just until contact is made.

03766B

FIG.6

TORQUE TO

11 N•m (8 ft–lb)

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