INSTRUCTIONS 684025 Revision E This manual contains important warnings and information. READ AND RETAIN FOR REFERENCE Instructions Air-Powered King and Premier Hydra-Cat® H.P. Variable Ratio Proportioning Pump 100 PSI (7 bar) Maximum Working Air Pressure 5000 PSI (333 bar) Maximum Working Fluid Pressure Model: See Chart Assembly Ratio Ratio Part # Min. Max. 965478 1.50 4.50 965466 3.00 9.00 965477 1.00 3.00 965479 2.00 6.00 965481 1.50 4.
Table of Contents Symbols.............................................................................3 Definition of Terms ............................................................3 Warnings ...........................................................................3 Specification of Hydra-Cat H.P. Pumps ............................6 Installation .........................................................................6 Connect the Fluid Supply Line ....................................
Symbols Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions. Definition of Terms WARNING: Alerts the user to avoid or correct conditions which could cause serious injury. BASE: Also called polyol or resin, is one of two reactive chemicals used in a plural component system.
WARNING FIRE AND EXPLOSION HAZARD Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and result in fire or explosion and serious injury. • Ground the equipment and the object being sprayed. See Electrical Grounding on page 8. • Extinguish all the open flames or pilot lights in the spray area. • Electrically disconnect all equipment in the spray area. • Keep the spray area free of debris, including solvent, rags, and gasoline.
WARNING INJECTION HAZARD Spray from the spray gun, hose leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause serious injury. • Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medical attention. • Do not point the gun at anyone or at any part of the body. • Do not put your hand or fingers over the spray tip.
Specifications of Hydra–Cat H.P. Pumps The following chart gives specifications for the Hydra-Cat H.P. pumps, using No. 10 weight oil. The volumetric ratio is expressed as the proportion of the volume of fluid of the primary pump compared to the volume of fluid of the secondary pump. Ratio Air Motor Assembly Min Max Part No. For example, Model 965477 has a minimum volumetric ratio of 1:1. At this setting the primary and secondary pumps combined will deliver an output of 3.0 gpm.
KEY A Bleeder Type Main Air Valve B Air Regulator C Pressure Relief Valve D Mix Manifold E Air Supply Line F Air Line Filter G Air Shutoff Valve H Air Line Lubricator J Base Supply Pump K Catalyst Supply Pressure Pot L Solvent Supply Pump M Mix Manifold Flush Inlet N Static Mixer P Primary Pump Inlet R Secondary Pump Inlet S Ratio Adjustment Screw T Spray Gun U Ratio Indicator Plate V Ratio Indicator Pin Fig. 2 Typical Installation System Accessories Connect the Air Supply Line Refer to Fig. 2.
Electrical Grounding 4. Spray gun or dispensing valve: Obtain grounding through connection to a properly grounded fluid hose and pump. WARNING 5. Fluid supply container: according to your local code. FIRE AND EXPLOSION HAZARD Static electricity is created by the high velocity flow of fluid through the pump and hose. If your system is not properly grounded, sparking may occur and the system may become hazardous.
Ratio Adjustment Understanding the terms used with the Hydra–Cat (H.P.) System, how it functions, and how to find and set the correct ratios for your application is the key to easier, more versatile operation of your proportional system. Be sure to read and understand the following information before operating the equipment. Terms Ratio refers to the simultaneous output of a certain volume of fluid by the primary and secondary pumps.
Determine the Ratio Set the ratio based on your situation. If : • • The fluids are supplied at a ready–to–spray viscosity, simply set the ratio as explained under Adjusting the Ratio. The fluids are NOT supplied at ready–to–spray viscosity, the ratio must be determined after the reducer is added to the base, as instructed in Procedure 1, below. NOTE: Evaporation of the reducer in the base causes changes in the ratio. To prevent evaporation, store the base in a closed container.
Operation WARNING INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection. To reduce the risk of parts, follow the Pressure Relief Procedure whenever you: • are instructed to relieve the pressure, • stop spraying, • check or service any of the system equipment, • or install or clean the spray tips.
Checking the Ratio Note: The mix ratio must be checked at the normal operating fluid pressure of the pump. Most mixer manifolds provide a means for checking mix ratio that includes needle valves for adjusting the fluid pressure during the test. The following procedure is an example of how to properly check the mix ratio. 1. Open the mixer manifold and trigger your spray gun. 2. Set your operating pressure. After determining the operating pressure, release the spray gun trigger and engage the safety latch.
Air Lubrication If your air supply Is very dry, install an air line lubricator between the air regulator and the pump air motor for automatic lubrication. Refer to the air motor manual for details. Make sure to use an Industrial Grade 1, Heavy Duty, Extreme Pressure, Lithium Soap Grease, Graco Part Number 110293 or equivalent. Replace the covers (17) and the bolts (16) after greasing, and before starting the machine.
Troubleshooting Troubleshooting Techniques 8. Because the pumps are mechanically linked, the action of one pump can affect the readings of the second pump. Therefore, the key to successful troubleshooting is to be sure to isolate the problem. With the main bleed-type air valve (1) off, remove the thumb screws (14) and guards (15) from each side of the proportioner. 9. Unscrew the connecting rod nut (10) from the primary pump. Now you can verify the operation of the secondary pump alone.
Troubleshooting Chart PROBLEM CAUSE SOLUTION System will not run or Air pressure or air stops while running. volume is too low. Increase air pressure. Check air compressor and air supply filters regulator, lubricator valves and other components for blockages and restrictions. If this is a new system, be sure that air supply components have been sized properly. The fluid valves or hoses are closed or restricted.
Service Required Tools • Set of large adjustable wrenches • Set of metric sockets or wrenches • Large pipe wrench • Torque wrench • Rubber mallet • Flat end punch 4. With the bleeder type main air valve turned off (1), remove the thumb screws (14) and the two guards (15) from the sides of the proportioner. 5. Disconnect the displacement pump (3) from the frame (5) as follows: 6. Note the relative position of the pump’s fluid outlet (23) to the frame and also note the frame location of removed.
Reconnecting the Displacement Pump CAUTION 1. Make sure the coupling nut (10,11) and the coupling collars (12) are in place on the displacement rod. See Fig. 6. Be sure to use an overhead hoist when lifting, moving or disconnecting the air motor. This air motor weighs 145 lbs. and is too heavy for one person to handle. A lift ring is provided on the motor for this purpose. 2.
Replacing the Bearings 1. Relieve the Pressure. Refer to Figure 6 and Figure 7. WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11. 2. With the bleeder type main air valve (1) turned off, remove the twenty hex bolts (16) with a 13mm wrench or socket and then remove the four sheet metal covers (17) from the front and back of the proportioner. The left rear cover may contain a sensor attached to a cable.
Dimensions (A) Height.......................................... 66.0 inch 1676 mm) (B) Length .......................................... 31.5 inch (800 mm) (C) Width ........................................... 33.0 inch (838 mm) (D) Air Inlet..........................................................3/4 npt(f) (E) Fluid Inlets..............................................Two, 2” npt(f) A (G) Fluid Outlet ..........................................Two 1/2” npt(f) (H) Relief Valve Outlets ....................
NOTES 20 684025
Technical Data Air motor effective diameter ....................................................................................Premier 12.64” (321 mm) ............................................................................................................................ King 10.00” (254 mm) Air motor stroke ...................................................................................................................... 4.75” (120 mm) Operating air pressure range 20 to 100 psi (1.
Graco Standard Warranty WARRANTY Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months or two thousand hours of operation from time of sale, repair or replace any part of the equipment proven defective.