Graco HYDRA-CAT FIXED RATIO Operation manual

308986
Rev. C
First choice when
quality counts.t
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP IT FOR REFERENCE.
HYDRA-CATrFIXED RATIO
Proportioning Pumps
Available as Bare Pumps,*
Wall-Mounted* or Free-Standing* Models
*Includes Automatic Pressure Relief Valves, Check
Valves, Pressure Gauges and
Regulators
ENTER CODE NUMBER ON LINE BELOW
FRHC–_–_ _ _–_ _–_–_ _–_ _–__–_
Enter Part No. _ _ _ _ _ _
NOTE: This manual is a reference when using
Configurated Hydracat and manual 309002.
02884A
Typical
Free Standing Assembly
Shown
WARNING
Plural Component Materials Hazard
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
reaction, before using this equipment the buyer and the user should determine all facts relating to the materials used, in-
cluding any of the potential hazards involved. Particular inquiry and investigation should be made into the potential dan-
gers 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 prop-
erty damage, direct or consequential, arising from the use of such chemical components.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441
ECOPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

2308986
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Information 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care of the System 30. . . . . . . . . . . . . . .
Troubleshooting 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service –Pneumatic Displacement pump 34. . . . . . . . .
Service –Hydraulic Displacement pump 36. . . . . . . . . .
Graco Warranty 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 40. . . . . . . . . . . . . . . . . . . . . . . . . .
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Manual No.

308986 3
Warnings
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in
serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, warnings, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck the equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated system component. See the
Technical Data section of all the equipment manuals.
DSee Configurator Product Order Form 309002 for important pressure rating information. The maxi-
mum working pressure of each model is also shown on the pump identification plate. Be sure that
all dispensing equipment and accessories are rated to withstand the maximum working pressure of
your pump. Do not exceed the maximum working pressure of the lowest rated system component.
DNever operate the pump without the automatic pressure relief valves and drainage kits installed.
These valves relieve fluid pressure through a drain port at the bottom of the valve if the displace-
ment pump pressure exceeds the working pressure.
DNever exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Configurator Product Order Form 309002 .
DDo not lift pressurized equipment.
DUse only Graco approved hoses. Do not remove hose spring guards, which help protect the hose
from rupture caused by kinks or bends near the couplings.
DRoute the hoses away from the 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).
DDo not use the hoses to pull the equipment.
DUse fluids and solvents that are compatible with the equipment wetted parts. See the Technical
Data section of all the equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DComply with all applicable local, state and national fire, electrical and other safety regulations.

4308986
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.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
DDo not point the gun/valve at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip/nozzle.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DDo not “blow back”fluid; this is not an air spray system.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DAlways have the trigger guard on the gun when dispensing.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe sure the gun/valve trigger safety operates before dispensing.
DLock the gun/valve trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 23 if the nozzle clogs, and before cleaning, check-
ing or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Do not repair high pressure couplings; you must replace the entire hose.
DFluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
FIRE, EXPLOSION AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in fire, explosion, or electrostatic shock and other serious injury.
DGround the equipment, the object being dispensed, and all other electrically conductive objects in
the dispense area. Proper grounding dissipates static electricity generated in the equipment. Refer
to System Grounding on page 11.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvent or material.
DDo not use the heater with flammable liquids, such as those having flash points below 200_F
(93_C).
DExtinguish all open flames or pilot lights in the dispense area.
DDo not turn on or off any light switch in the dispense area.
DDo not use this equipment with flammable liquids.
DKeep the dispense area free of debris, including solvent, rags, and gasoline.
DDo not smoke in the dispense area.
DDo not operate a gasoline engine within the spray area.
DIf there is any static sparking or you feel an electric shock while using the equipment, stop dis-
pensing immediately. Do not use the equipment until you have identified and and corrected the
problem.

308986 5
WARNING
MOVING PARTS HAZARD
Moving parts can pinch fingers.
DKeep clear of all moving parts when starting or operating the equipment.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
DAvoid exposure to heated material fumes.
DProvide adequate ventilation.
DGraco does not manufacture or supply any of the reactive chemical components that may be
used in this equipment and is not responsible for their effects. Graco assumes no responsibility
for loss, damage, expense or claims for personal injury or property damage, direct or conse-
quential, arising from the use of such chemical components.

6308986
System Information
This manual describes pumps designed to be part of a
Hydra-Cat dispensing system that will proportion, mix,
and dispense two-component fluids. The fixed ratio
proportioners accurately pump and proportion two–
component materials by powering two or three positive
displacement pump lowers from a common air motor.
This assures that the stroke rate and stroke length of
all pump lowers are identical, providing constant pro-
portioning. The mix ratio is fixed by selecting compat-
ible sets of two or three lowers (see Configurator
Product Order Form 309002 ).
The basic proportioner includes an air motor, lower
displacement pumps, air controls, fluid inlet hardware,
fluid outlet hoses, manifold blocks and relief valve.
Additional proportioner accessories are selectable to
complete the proportioner pump (see Configurator
Product Order Form 309002 ).

308986 7
Typical Installation
About Typical Installations
The typical installations shown below and on pages 8
and 9 are only guidelines to setting up a complete
proportioning system. For clarity, various components
are shown in the correct order but may not be shown in
the exact position of the installed system. For assis-
tance in designing your system, contact your nearest
Graco representative.
NOTE: When pressure feeding the proportioning
pump, mount fluid pressure gauges (J) at the propor-
tioning pump inlets to monitor proper adjustment of the
feed pump pressures. Never exceed 400 psi on the
inbound fluid pressure and never exceed 25% of
the Hydra-Cat pump outbound fluid pressure on
the feed supply.
Two Displacement Pumps,
with Feed Pumps
1See note above
Connect to drain bottle.
See Fig. 6, page 13
2
KEY
A Bleed-type master
air valve
B Air filter
C Air lubricator
D Pump runaway valve
E Pump air regulator
F Feed pump
G Ground wire
H Proportioning pump
J Fluid pressure gauge
K Check valve
L Automatic pressure relief
valve
M Fluid filter (Optional)
N Mixer manifold
P Fluid drain valve
Q Fluid shutoff valve
R Static mixer
S Dispense valve
T Fluid regulator
U Solvent pump
V Fluid strainer
Fig. 1
BA
FG
A
E
HKL
M
N
P
Q
R
Q
K
S
M
J
T
Q
A
E
V
U
1
02911
2
C
D

8308986
Typical Installation
About Typical Installations
The typical installation shown below, and on pages 7
and 9, are only a guidelines to setting up a complete
proportioning system. For clarity, various components
are shown in the correct order but may not be shown in
the exact position of the installed system. For assis-
tance in designing your system, contact your nearest
Graco representative.
NOTE: When pressure feeding the proportioning
pump, mount fluid pressure gauges (J) at the propor-
tioning pump inlets to monitor proper adjustment of the
feed pump pressures. Never exceed 25% of the
Hydra-Cat pump outbound fluid pressure on the
feed supply.
Heavy Viscosity Heated Feed System with
Three Displacement Pumps
1
2
See note above
Connect to drain bottle.
See Fig. 6, page 13
KEY
A Bleed-type master air valve
B Air filter
C Air lubricator
D Pump runaway valve
E Pump air regulator
F Feed pump
G Ground wire
H Proportioning pump
J Fluid pressure gauge
K Check valve
L Automatic pressure
relief valve
M Fluid filter (Optional)
N Mixer manifold
P Fluid drain valve
Q Fluid shutoff valve
R Static mixer
S Dispense valve
T Fluid regulator
U Solvent pump
V Fluid strainer
W Flow control valve
X Supply manifold
Z Fluid heater
02912
Fig. 2
D
BA
C
FGAE
2
HJKLM
N
P
Q
R
Q
K
S
M
J
T
Q
AE
V
U
1
X
2
Z
W

308986 9
Typical Installation
About Typical Installations
The typical installation shown below, and on pages 7
and 8, are only a guidelines to setting up a complete
proportioning system. For clarity, various components
are shown in the correct order but may not be shown in
the exact position of the installed system. For assis-
tance in designing your system, contact your nearest
Graco representative.
Hydraulic Pump
7354A
Fig. 3
F
B
Y
C
D
A
E
G
H
J
KEY
AHydraulic Pump
BMounting Stand
CHydraulic Supply Line
DHydraulic Return Line
EDrain Line (from pressure reducing valve)
FPressure Gauge
GFlow Control Valve
HPressure Reducing Valve
JAccumulator
KFeed Pumps
PHydraulic Supply Line Shutoff Valve
RHydraulic Return Line Shutoff Valve
SHydraulic Return Line Filter
UHydraulic Power Supply
VFluid Hose
WFluid Supply Line
YPump Ground Wire (required; see page 11
for installation instructions)
K
P
S
K
R
U
VW

10 308986
Installation
Bare Pumps
Bare pumps, with relief valves and inlet kits but without
stands, are available for those installations which
require a highly customized system. For a safe and
efficient system, Graco recommends that the air and
fluid components supplied with the Wall Mount and
Stand models also be used in customized systems. In
addition, the accessories shown in the Typical Installa-
tion drawings and discussed in the following pages of
this manual should be used.
Be sure all accessories are sized properly for the air
and fluid requirements of your system.
Read all instructions in the Installation section for
further details.
NOTES:
1. Models with three displacement pumps always use
the two outer displacement pumps to supply the
resin and the middle displacement pump to supply
the hardener.
2. Label all pumps, hoses, fluid regulators, etc. to
indicate whether they are for the resin side or
hardener side of the system.
Mounting the Pump
Mount the pump to suit your installation. The bare
pump can be mounted on a wall bracket or on a stand.
See the Mounting Hole Layout on page 19.
For a wall mount, be sure the bracket and wall are
strong enough to support the pump, accessories,
plumbing and stress caused by pump operation.
Locate the bracket about 5 ft (1.5 m) above the floor.