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.

308986 11
Installation
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding could cause static
sparking, which could cause a fire or
explosion. To reduce the risk of property
damage or serious injury, follow the
grounding instructions below.
The following grounding instructions are minimum
requirements for a system. Your system may include
other equipment or objects which must be grounded.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment. Your
system must be connected to a true earth ground.
1. Pump:
a. Loosen the grounding lug locknut (Fig. 4,
Item BB) and washer (AA).
b. Insert one end of a 14 ga. (1.5 mm@) minimum
ground wire (G) into the slot in lug (CC) and
tighten the locknut securely.
c. Connect the other end of the ground wire to a
true earth ground.
Fig. 4
G
BB AA
CC
G
BB
AA CC
Select you application
Available Accessories (must be
purchased separately)
1. Air hoses: use only grounded hoses with a maxi-
mum of 500 feet (150 m) combined hose length to
ensure grounding continuity.
2. Air and Paint Line Filters: locate all filters and
learn all filter cleaning procedures before operating
the system. Optional filters are available to meet
particular system needs. Be sure all filters are
checked and cleaned every day.
3. Filters: be sure your hydraulic power supply (U) is
equipped with a suction filter to the hydraulic pump
and a system return line filter (S) of 10 micron size.
Carefully follow the manufacturer’s recommendations
on reservoir and filter cleaning, and periodic changes
of hydraulic fluid. Use only Graco approved hydraulic
oil. Order Part No. 169–236, 5 gallon (19 liter) or
207–428, 1 gallon (3.8 liter).
4. Hydraulic Line Accessories: on the hydraulic
supply line (Item C, Fig. 3), install the following
accessories in the order shown in Fig. 3, using
adapters as necessary.
CAUTION
It is very important to keep the hydraulic supply
system clean at all times. Be sure that all hydraulic
fluid lines are absolutely clean. Blow out the lines
with air and flush thoroughly with solvent before
connecting to the hydraulic motor, to avoid introduc-
ing harmful contaminants into the motor.
For optimum pump performance, keep the tempera-
ture of the hydraulic oil below 130_F (54_C).
a. Shutoff valve (P): to isolate the pump for
servicing.
b. Fluid pressure gauge (F): to monitor hydraulic
oil pressure to the motor and to avoid over-
pressurizing the motor or displacement pumps.
c. Pressure and temperature-compensated flow
control valve (G): to prevent the motor from
running too fast and possibly damaging itself.
d. Pressure reducing valve (H) with drain line (E):
running directly into the hydraulic return
line (D).
e. Accumulator (J): to reduce the hammering
effect caused by the motor reversing direction.

12 308986
Installation
Available Accessories (Cont’d)
On the hydraulic return line (D), install the following
accessories in the order shown in Fig. 3, using adapt-
ers as necessary.
f. shutoff valve (R): to isolate the pump for serv-
icing.
g. Filter (S): 10 micron size.
Install the following accessories in the order shown in
Fig. 3, using adapters as necessary.
WARNING
A fluid drain valve (L) is required in both fluid lines
to the gun, to help reduce the risk of serious injury,
including splashing of fluid in the eyes or on the
skin.
The fluid drain valve assists in relieving fluid pres-
sure in the displacement pump, hose, and spray
gun. Triggering the gun to relieve pressure may not
be sufficient.
h. Fluid drain valves (L): are required in your
system to relieve fluid pressure in the hose
and gun (see the WARNING above).
5. Fluid hoses: use only grounded fluid hoses.
6. Hydraulic Power Supply or Air compres-
sor: follow manufacturer’s recommendations.
7. Spray gun or dispensing valve: grounding is
obtained through connection to a properly
grounded fluid hose and pump.
8. Fluid supply container: according to local code.
9. Object being sprayed: according to your local
code.
10. All solvent pails used when flushing,according
to local code. Use only metal pails, which are con-
ductive, placed on a grounded surface. Do not place
the pail on a nonconductive surface, such as paper
or cardboard, which interrupts the grounding continu-
ity.
11. To maintain grounding continuity when flush-
ing or relieving pressure,always hold a metal
part of the dispensing unit firmly to the side of a
grounded metal pail, then trigger the dispensing
unit.

308986 13
Installation
Air Control Accessories
Install the accessories in the order shown in Fig. 5.
Mount only the air regulator (E) and a master air
valve (A) at the pump. Mount all other accessories on
separate wall brackets to reduce stress on the pump
inlet. Note that one air filter (B) can serve multiple
pumps by using an air manifold downstream from the
air filter.
WARNING
INJECTION HAZARD
Bleed-type master air valves (A) are required in the
system in the positions shown in the Typical Instal-
lation drawings. These valves are used during
system pressure relief to relieve air trapped in the
air line. Trapped air can cause the pump to cycle
unexpectedly and result in serious injury from
moving parts, fluid injection, or fluid splashing.
02887
Fig. 5
D
BA
C
G
AE
NOTE: Instalation of pump runaway valve (D):
–For Bulldog Air Motors: install runaway valve (D) before
the air regulator (E) and air motor (F).
–For Monark and President Air Motors: install runaway
valve (D) between the air regulator (E) and air motor (F).
F
Bulldog setup shown
1. Install a bleed-type master air valve (A) in the
pump air inlet.
2. Install an air regulator and gauge (E) to control
pump outlet pressure.
3. Install a pump runaway valve (D) for each feed
pump to automatically shut off the air to the pump
if the pump accelerates beyond the pre-adjusted
setting. A pump which runs too fast can be seri-
ously damaged.
4. Install an air line lubricator (C) for automatic air
motor lubrication.
5. Install an air filter (B) to remove harmful dirt and
moisture from the compressed air supply.
Automatic Pressure Relief Valves
See Fig. 6.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of component rupture,
which could cause serious injury and
property damage, the appropriate auto-
matic pressure relief valve (A) is required for each
fluid on a plural component pump.
These valves automatically relieve fluid pressure if
the pump output pressure exceeds the valve’s
preset pressure. Over-pressurization may occur if
there is a fluid line clog upstream from the valve or
if any other condition exists that causes one of the
pumps to cavitate and direct all fluid pressure to
the other pump(s).
See Configurator Product Order Form 309002 to
determine the preset pressure in your system.
Fig. 6
B
02888A
A
NOTE: Drainage Bottle Kit
includes items fastening hard-
ware shown

14 308986
Installation
Automatic Pressure Relief Valves
(continued)
Fig. 6. Two drain bottle kits (B) are included with the
stand mount models to catch the drainage if the auto-
matic pressure relief valves (A) open.
WARNING
INJECTION HAZARD
Be sure to use the drain bottles and drain lines
provided. If system pressure is exceeded, fluid
emitted from the automatic pressure drain valves
may be at pressures over 3000 psi (21 MPa, 207
bar). To reduce the risk of serious injury from fluid
injection or fluid splashing, make sure the drain
bottles are securely fastened to the frame or wall
so that they can handle a sudden discharge of
pressurized fluid. Discharged fluid on floors can
also cause a slipping hazard if not collected.
Connect Fluid Supply Hoses
NOTE: If you mount the pump on a wall, turn the
displacement pump inlet assemblies (CC) to face
forward, rather than backwards as shown in Fig. 7.
Two Displacement Pump Models
1. Connect the resin supply hose (EE) to the 3/4 npt
swivel inlet (37B) for the resin displacement pump.
See Fig. 7.
2. Connect the hardener supply hose (DD) to the
3/4 npt swivel inlet (37A) for the hardener displace-
ment pump. See Fig. 7.
Three Displacement Pump Models
1. Connect the resin supply hose (EE) to the 3/4 npt
swivel inlet (37B) for the resin displacement
pumps. See Fig. 8.
2. Connect the hardener supply hose (DD) to the 3/4
npt swivel inlet (37) for the center (hardener)
displacement pump. See Fig. 8.
Additional System Components
Install and connect the feed pumps, solvent pump,
heaters, etc. Refer to the Typical Installations
(pages 7, 8 and 9) for parts information.
Use a dry air kit or a nitrogen regulator kit to protect
the fluid in the supply containers from moisture that
can crystallize the fluid and cause the ball checks to
malfunction. See Accessories in Configurator Product
Order Form 309002 .
Fig. 7
DD
EE
CC
RES
HARD
02889
37B
37A
Fig. 8
DD
EE
HARD
37B
37A
02890
RES
RES

308986 15
Installation –Optional Fluid Heaters
Fig. 9
201
202
203
204
10
201a
201b
IN
OUT
02913A
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the Pressure Relief Procedure
on page 23 before installing the heaters.
All Models
1. See Fig. 9. Mount a heater to each side of the
mounting bracket using the three screws (201a)
and lockwashers (201b) supplied with each heater.
2. Connect a swivel union (202) to the outlet of each
heater.
3. Connect a swivel union (203) to the inlet of each
heater.
CAUTION
Use heaters for unmixed material only. Heating
mixed material will cause the mixture to solidify in the
heater making the heater unusable.
Heaters can be used to heat separate material
components before mixing. Material can also be
heated in a circualtion feed system or between the
outlet of the material pump and the mix manifold.

16 308986
Installation –Optional Fluid Heaters
Two Displacement Pump Models
1. See Figs. 10 and 11. Loosen swivels of unions
(17A and 17B) to remove elbows (16A and 16B)
on each side of mixer manifold (23). Turn unions
(17A and 17B) so outlets faces up.
2. Connect new hardener fluid hose (204B) between
union (17B) and swivel (203B) at heater inlet.
3. Install another hardener fluid hose (FB) between
heater outlet elbow (202B) and hardener side of
mixer manifold (23).
4. Repeat Steps 1 to 3 for resin side of system (“A”
side).
See Three Displacement Pump Models on next page.
Fig. 10
204B
IN IN
OUT
OUT
IN
OUT
RES
HEATER
IN
OUT
HARD
HEATER
RES HARD
RES HARD
17A 17B
202A 202B
203B203A
23
205A
FA FB
RES
HARD
02892A
Fig. 11
16B
16A
17B
17A
23
RES
HARD

308986 17
Installation –Optional Fluid Heaters
IN
OUT
RES
HEATER
IN
OUT
HARD
HEATER
RES
HARD
RES
RES HARD
RES HARD
Fig. 12
17A 17B
202A 202B
203B203A
23
204B
205A
FA FB
02894
Three Displacement Pump Models
1. Loosen the swivel of the unions (17A, 17B) to
remove the elbow (16A, 16B) on each side of the
mixer manifold (23). Turn the unions (17A, 17B) so
the outlet faces up. See Figs. 12 and 13.
2. Connect a new hardener fluid hose (204B)
between the union (17B) and the swivel (203B) at
the heater inlet. See Fig. 12.
3. Install another hardener fluid hose (FB) between
the heater outlet elbow (202B) and the hardener
side of the mixer manifold (23). See Fig. 12.
4. Repeat Steps 1 to 3 for the resin side of the
system (the “A”side).
02892A
Fig. 13
16B
16A
17B
17A
23
RES
HARD

18 308986
Installation –Optional Solvent Pump
NOTE: The optional solvent pump is not offered as a
kit; order parts as needed. These instructions assume
that the pump is being mounted to the back of the
stand offered in this manual. The Typical Installations
on pages 7 and 9 showsan alternate installation.
Adjust your installation according to your specific
needs.
1. Mount the solvent pump bracket (310) on the back
of the stand.
2. Mount the pump (306) to the bracket using the
hardware supplied with the pump.
3. Use the existing proportioning pump air
regulator (5) to supply air to the solvent pump.
Remove the plug from the back of the swivel
union (3) and install the adapter (301). Rotate the
regulator gauge elbow (4) so the gauge is facing
the operator.
4. Couple the hose (303) and couplings (302).
Connect the hose (303) to the adapter (301).
5. Install the other adapter (301), needle valve (304)
and adapter (305) to the pump inlet.
6. Connect the adapter (307), elbow (308) and fluid
hose (309) to the pump outlet.
7. Install a fluid shutoff valve (311) at the mixer
manifold swivel union (15). This valve is used to
prevent resin or hardener from backing up into the
solvent system, and to isolate the solvent system
for service. Connect the solvent inlet hose (309).
8. Connect the suction hose assembly (312) to the
pump intake.
309
310
312
308
307
305
303
301
304
314
313
301
309
311
15
306
316
315
Fig. 14
302,
303
302
5
4
3
A
B
02902
B
A
Monarch 10:1 Shown

308986 19
Dimensions
BulldogR14–34”(375 mm)
KingR21.5”(534 mm)
PresidentR16.06”(408 mm)
ViscountR11.2”(284.48 mm)
ViscountRII 18.6”(472 mm)
1
3
4
2
1
3
4
2
5
7
6
7
6
5
32–3/4”(832 mm)
28–1/4”(718 mm)
17–3/4”(451 mm)
30–1/4”(768 mm)
11”(279 mm)
12–1/2”(318 mm)
02910A

20 308986
Flushing
When to Flush the System
DFlush the system before its first use to remove the
light oil which was left in after factory testing.
DFlush the manifold mixer (N), using the solvent
pump, as frequently during the day as necessary to
avoid exceeding the pot life limit of the material
being pumped.
DFlush frequently enough during regular operation to
prevent clogged passages due to material being
overheated or dried out in any part of the system.
Clogged passages in the heater can be very difficult
to clean and can reduce heating efficiency, flow rate
and pressure.
DFlush the entire system when the system is shut
down for a long period of time. Keep in mind that
some moisture may get into the lines, which could
contaminate the hardener, so flush again before
restarting the system.
How to Operate the Mixer Manifold
Push handle (KK) down to open or up to close the
mixer manifold fluid valves (LL) . See Fig. 15.
Fig. 15
1
2
UP –closed
DOWN –open
1
2
KK
LL
LL
N2
N1
N
P2
P1
02895
RES
HARD
02914
Fig. 16
A3
E3
A2
E2
H
J1 J2
KEY
A Bleed-type master air valve
A1 Hardener feed pump
A2 Resin feed pump
A3 Proportioning pump
A4 Solvent pump
A5 Feed and Proportioning pump master
air valve
A6 Solvent pump master air valve
E Pump air regulator
E1 Hardener feed pump
E2 Resin feed pump
E3 Proportioning pump
E4 Solvent pump
J Fluid pressure gauge
J1 Proportioning pump intake
J2 Proportioning pump outlet
H Proportioning pump
N Mixer manifold
Q Fluid shutoff valve
Q1 Proportioning pump intake
Q2 Mixer manifold solvent inlet
A1
E1
A5 A6
A4
E4
N
Q2
Q1