Graco Hydra-Cat H.P. Series User manual

INSTRUCTIONS 684025
Revision E
Instructions
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
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
WARNING
MOVING PARTS HAZARD
Relieve fluid and air pressure to unit before
servicin
g
unit. Do not operate with panels
removed. Follow pressure relief procedure on
page 11.
WARNING
Graco Inc. does not manufacture or suppl
y
an
y
of the reactive chemical components that are used in this equipment
and is not responsible for their effects. Because of the vast number of chemicals that could be used and their
var
y
in
g
chemical reactions, the bu
y
er and user of this equipment should determine all factors relatin
g
to the fluids
used, includin
g
an
y
of the potential hazards involved. Particular inquir
y
and investi
g
ation should be made into
potential dan
g
ers relatin
g
to toxic fumes, fires, explosions, reaction times, and exposure of human bein
g
s to the
individual components or their resultant mixtures. Graco assumes no responsibilit
y
for loss, dama
g
e, expense or
claims for bodil
y
injur
y
or propert
y
dama
g
e, direct or consequential, arisin
g
from the use of such chemical
components.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 1998 Graco Inc.
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 4.50

2 684025
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....................................6
Connect the Fluid Output Lines ..................................6
System Accessories ...................................................7
Connect the Air Supply Line .......................................7
Pressure Relief Valve .................................................7
Electrical Grounding ...................................................8
Ratio Adjustment...............................................................9
Terms .........................................................................9
Determine the Ratio..................................................10
Relationship Between the Primary and
Secondary Pumps .................................................10
Adjusting the Ratio Setting .......................................10
Operation...................................................................... 11
Pressure Relief Procedure..................................... 11
System Flushing .................................................... 11
Start the Pump....................................................... 11
Standard Operating Flushing ................................. 11
Checking the Ratio ................................................ 12
Maintenance................................................................. 12
Wet Cups ............................................................... 12
Bearings................................................................. 12
Air Lubrication........................................................ 13
Troubleshooting............................................................ 14
Troubleshooting Techniques ................................. 14
Troubleshooting Chart ........................................... 15
Service ......................................................................... 16
Required Tools ...................................................... 16
Disconnecting the Displacement Pump................. 16
Reconnecting the Displacement Pump ................. 17
Disconnecting the Air Motor................................... 17
Reconnecting the Air Motor ................................... 17
Replacing the Bearings.......................................... 18
Dimensions................................................................... 19
Air Consumption........................................................... 19
Technical Data ............................................................. 21
Graco Information ........................................................ 22
Graco Standard Warranty ............................................ 22

684025 3
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 dama
g
e 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.
CAUTION: Alerts the user to avoid or correct conditions
which could damage or destroy equipment.
NOTE: Identifies helpful information.
VRHC: The abbreviation for Variable Ratio Hydra–Cat
Pump. This pump automatically proportions and mixes two
fluids in a prescribed ratio, which is variable within the
ranges listed on the cover.
BASE: Also called polyol or resin, is one of two reactive
chemicals used in a plural component system.
CATALYST: Also called hardener, is the fluid which reacts
with the base fluid.
PART: An undefined unit of measurement. When you
determine the size of the unit (ounce, pint, gallon), use that
measurement consistently in setting up your system.
SPRAY GUN: This term refers to any type of spray gun or
dispensin
g
valve used to spray or dispense the fluid bein
g
pumped.
WARNING
PLURAL COMPONENT FLUID HAZARD
Before usin
g
this equipment, read the fluid manufacturer’s warnin
g
s and determine all facts relatin
g
to the
fluids used, includin
g
any of the potential hazards relatin
g
to toxic fumes, fires, explosions, reaction times,
and exposure of human beings to the individual components of their resultant mixtures.
•Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state
and national guidelines.
•Wear the appropriate protective clothing, gloves, eyewear, and respirator.
•Graco 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,
dama
g
e, expense or claims for personal injury or property dama
g
e, direct or consequential, arisin
g
from the use of such chemical components.
MOVING PARTS HAZARD
Movin
g
parts, such as the air motor piston and the secondary pump lever and connectin
g
rod area, can
pinch or amputate fingers.
•Do not operate the equipment with the guards removed.
•Keep your body and tools clear of any moving parts when starting or operating the equipment.

4 684025
WARNING
FIRE AND EXPLOSION HAZARD
Improper
g
roundin
g
, 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.
•Do not turn on or off any light switch in the spray area while operating or if fumes are present.
•Do not smoke in the spray area.
•Do not operate a gasoline engine in the spray area.
•If there is any static sparking while using this equipment, stop spraying immediately. Identify and
correct the problem.
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly 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 uncertain about the usa
g
e, call your Graco
distributor.
•Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
•Check the equipment daily. Repair or replace worn or damaged parts immediately.
•All system components must meet or exceed the pressure ratin
g
s printed on the pressure relief valve.
The lever amplification or the secondary pump enables very hi
g
h fluid pressures to be achieved. A
5000 psi workin
g
pressure ran
g
e relief valve is required on both cylinders to limit the fluid pressure. Do
not tamper with the pressure relief valve or serious bodily injury could result.
•Do not lift pressurized equipment.
•Route the hoses away from the traffic areas, sharp ed
g
es, movin
g
parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180ºF (82ºC) or below -40ºF (-40ºC).
•Do not use hoses to pull equipment.
•Use fluids or 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.
•Fluid hoses must have sprin
g
g
uards on both ends to protect them from rupture caused by kinks or
bends near the couplings.
•Comply with all applicable local, state, and national fire, electrical, and safety regulations.

684025 5
WARNING
INJECTION HAZARD
Spray from the spray
g
un, hose leaks or ruptured components can inject fluid into your body and cause
extremely serious injury, includin
g
the need for amputation. Splashin
g
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.
•Do not stop or deflect leaks with your hand, body, glove or rag.
•Do not “blow back”fluid; this is not an air spray system.
•Always have the tip guard and the trigger guard on the spray gun (if so equipped) when spraying.
•Check the spray gun diffuser (if so equipped) operation weekly. Refer to the gun manual.
•Be sure the spray gun trigger safety operates before operating the gun.
•Lock the spray gun trigger safety when you stop spraying.
•Follow the Pressure Relief Procedure on page 11 when you are instructed to relieve pressure, stop
spraying, check, clean or service any system equipment, or install or change spray tips.
•Tighten all fluid connections before each use.
•Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
Permanently coupled hoses cannot be repaired.
•Handle and route hoses and tubes carefully. Keep hoses and tubes away from moving parts and hot
surfaces. Do not use the hoses to pull equipment. Do not expose Graco hoses to temperatures above
180ºF (82ºC) or below -40ºF (-40ºC).

6 684025
Specifications of Hydra–Cat H.P. Pumps
The followin
g
chart
g
ives specifications for the Hydra-Cat
H.P. pumps, usin
g
No. 10 wei
g
ht 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.
For example, Model 965477 has a minimum volumetric
ratio of 1:1. At this settin
g
the primary and secondary
pumps combined will deliver an output of 3.0
g
pm. The
maximum volumetric ratio for Model 965477 is 3:1 and the
combined output at that setting is 2.0 gpm.
Ratio At Minimum Ratio Settin
g
At Maximum Ratio Settin
g
Lower ID
Air Motor Assembl
y
Min Max Stall Stall
O
utput
O
utput Stall Stall
O
utput
O
utput Master Slave
Part No. PSI Bar GPM LPM PSI Bar GPM LPM DF DF
Premier
965
4
8
11.
50
4.
50
5333
368
3
.
8
14.4 727
3
50
22.
8
1
0
.
6
9
6
Premier
965
47
9
2.
00
6
.
00
4444
30
74.
6
17.
3
5
714
39
4
3
.
6
1
3
.4 12
6
Kin
g
965
477 1.
00
3
.
00
3803
2
6
2
3
.
0
11.
5
5
7
0
4
393
2.
0
7.7
6
6
Kin
g
965
47
8
1.
50
4.
50
30
42 21
0
3
.
8
14.4 414
8
2
86
2.
8
1
0
.
6
9
6
Kin
g
965
4
66
3
.
00
9
.
00
1
90
11
3
1
6
.1 2
3
.
0
22
8
21
5
7
5
.1 1
9
.2 1
8
6
Note: All Output Pressures Limited To 5000 PSI By Integral Pressure Relief Valves
Note: Pressure outputs calculated at 100 PSI Air Pressure for Premier and 90 PSI Air Pressure for King
Note: Volume outputs calculated at 40 cycles per minute.
Installation
The Typical Installation shown is only a
g
uide to settin
g
up
the complete Hydra-Cat H.P. system. For assistance in
desi
g
nin
g
a system to suit your particular needs, contact
your nearest Graco representative.
NOTE: The reference numbers and letters in the text
correspond to the numbers and letters in the drawings.
Location
Sit the proportioner on a flat floor surface.
Connect the Fluid Supply Lines
Connect the
g
rounded fluid hoses to the pump inlet fittin
g
s
(P, R). If the unit will be pressure fed from separate supply
units, install a fluid pressure gauge at each inlet.
NOTE: The pressurized fluid supplies must not exceed 1/4
of the operatin
g
fluid pressure of the pump. Pressure above
that level will feed ri
g
ht throu
g
h the pump and improper
rationing will result.
Connect the Fluid Output Lines
Connect electronically conductive fluid hoses to the pump
outlet fittings. Tighten all of the fittings.
Fig. 1

684025 7
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.
NOTE: To ensure the maximum pump performance and
safety, be sure that all the accessories used are properly
sized to meet your system requirements and the pressure
limits of the pump. Use only
g
enuine Graco parts and
accessories.
In the air line, install an air filter (F) to remove harmful dirt
and moisture from the compressed air supply. Install an air
line lubricator (H) downstream from the air filter, the air
re
g
ulator (B) and the bleed-type master air valve (A). A
lubricator will provide automatic lubrication to the air motor.
Connect an electrically conductive air supply hose to the
3/4”npt(f) port of the air manifold (B). Open the bleed-type
master air valve (A) and, usin
g
the pressure
g
au
g
e, set the
air re
g
ulator (B) to the desired pressure. See the Typical
Installation and the Parts Drawing.
Pressure Relief Valve
All components have rated workin
g
pressures of 5000 psi
(345 bar) or
g
reater. For more information about the
pressure relief valve, see instruction manual 308547.
WARNING
A bleed-type master air valve (A) is required in your
system to relieve the air trapped between the valve and
the pump after the pump is shut off. Trapped air can
cause the pump to cycle unexpectedly, resultin
g
in
possible serious injury, including amputation.

8 684025
Electrical Grounding
WARNING 4.
Spray gun or dispensing valve: Obtain grounding
throu
g
h connection to a properly
g
rounded fluid hose
and pump.
FIRE AND EXPLOSION HAZARD
Static electricity is created by the hi
g
h velocity
flow of fluid throu
g
h the pump and hose. If your
system is not properly
g
rounded, sparkin
g
may
occur and the system may become hazardous.
To reduce the risk of static sparkin
g
which can
result in a fire or explosion and cause serious
injury, follow these recommendations for
providin
g
electrical continuity throu
g
hout your
system.
Also, read the WARNING section, FIRE AND
EXPLOSION HAZARD on page 4.
5.
Fluid supply container: according to your local code.
6.
Object being sprayed: according to local code.
7.
All solvent pails used when flushing, according to local
code.
Use only metal pails which are conductive,
placed on a positively
g
rounded surface. Do not place
the pail on a non-conductive surface, such as paper or
cardboard, which interrupts the grounding continuity.
8.
To maintain grounding continuity when flushing or
relieving pressure,
always hold a metal part of the gun
or dispensin
g
valve firmly to the side of a
g
rounded
metal pail, then trigger the gun.
1. Pump: Loosen the grounding lug locknut (A) and
washer. Insert one end of a 12
g
a (1.5 m2) minimum
g
round wire (B) into the slot in the lu
g
(C). Ti
g
hten the
locknut securely. See Fi
g
. 3. Connect the other end of
the
g
round wire to a true earth
g
round. Order a
Groundin
g
Clamp, P/N 103538, and a Groundin
g
Wire,
P/N 208950, (25 feet (7.6 m) long, 12 ga.).
2.
Air and fluid hoses: Use only electrically conductive
hoses with a maximum of 500 feet (150 m) combined
hose length to ensure grounding continuity.
3.
Air compressor: follow the air compressor
manufacturer’s recommendations
Fi
g
.3
0720
A
B
C

684025 9
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 followin
g
information
before operating the equipment.
Terms
Ratio refers to the simultaneous output of a certain volume
of fluid by the primary and secondary pumps.
The primary pump (A) is directly under the air motor (H);
it usually pumps the base fluid. The secondary pump (B)
is on the opposite end of the lever arm (E); it usually
pumps the catalyst. The ratio of the secondary pump(s)
can be changed by adjusting the ratio adjustment screw
(C). See Fig. 4.
There are three main steps when applying the use of ratios:
(1) determine the ratio that is required, (2) calculate the
ratio setting, and (3) set the ratio on the Hydra-Cat H.P.
system.
Key
A Primary Pump
B Secondary Pump
C Ratio Adjustment Screw
D Wet Cups
E Fulcrum and Arm
F Primary Pump Output
G Secondary Pump Output
H Air Motor
I Air Input
J Bleed Type Master Air Valve
Fig. 4

10 684025
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
chan
g
es in the ratio. To prevent evaporation, store
the base in a closed container.
NOTE: Some reducers have very little ability to lubricate
and many cause seals to dry out. To prolon
g
the
seal life, be sure your pump seals are compatible
with the base’s reducer. Contact your Graco
representative for the correct seals to use.
Procedure 1: Base is not pre-reduced
When addin
g
the reducer to the base before proportionin
g
with the VRHC system, determine the ratio of the
base/reducer mixture to the catalyst in order to set the
proper ratio.
Example:
The instructions on the can say “Mix 5 parts base to 1 part
catalyst. Then reduce 3 parts of this mixture to 1 part
reducer.”
1. Add the parts of the base and catalyst to find the parts
mixture.
5parts base
+ 1parts catalyst
6parts mixture
2. The next statement on the can says, “Reduce 3 parts of
the mixture.”So divide the parts of the mixture by 3 parts
to reduce to find the parts reducer.
6parts mixture
/ 3parts to reduce
2parts reducer
3. To determine the ratio of the secondary pump, add the
appropriate parts of base and reducer to find the parts
combined base/reducer.
5parts base
+ 2parts reducer
7parts combined base/reducer to
1 part catalyst
The ratio of the pump is 7:1.
Relationship Between the Primary and
Secondary Pumps
Movin
g
the fulcrum point away from the primary pump
reduces the secondary stroke len
g
th, reducin
g
its fluid
output. Movin
g
the fulcrum point closer to the primary pump
increases the secondary stroke len
g
th, increasin
g
its fluid
output.
Fi
g
. 5 shows the relationship between the primary pump
and the secondary pump.
Adjusting the Ratio
See Fi
g
. 2. Use a wrench to rotate the ratio adjustment
screw (S). Rotatin
g
the screw clockwise will increase the
ratio. Rotatin
g
the screw counterclockwise will decrease
the ratio. The indicator pin (V) will move alon
g
the ratio
indicator scale (U) as the ratio adjustment screw is rotated.
When the pin is above the desired ratio, remove the
wrench and perform a ratio test as described on page 12.
Fig. 5