Graco Hydra-Cat Xtreme XL Parts list manual

Instructions-Parts
Hydra Hydra
Hydra- - -Cat® Cat® Cat®H.P. H.P. H.P.Variable Variable VariableRatio Ratio Ratio
Proportioning Proportioning
ProportioningPump Pump Pump3A3092A
EN
Adjustable Adjustable
Adjustable- - -ratio ratio ratioproportioner proportioner proportionerfor for forapplying applying applyinghigh high highsolids solids solidsprotective protective protectivecoatings. coatings. coatings.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinrelated
manuals.Savetheseinstructions.
SeeModels,page6.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Warnings...........................................................3
Models...............................................................6
RelatedManuals................................................6
Installation..........................................................7
Location......................................................7
ConnecttheFluidSupplyLines.....................7
ConnecttheFluidOutputLines.....................7
SystemAccessories.....................................8
ConnecttheAirSupplyLine..........................8
PressureReliefValve...................................8
Grounding..........................................................8
AdjustRatio........................................................9
DeterminetheRatio.....................................10
Procedure1:AddReducertothe
Base..............................................10
AdjustingtheRatio.......................................11
PressureReliefProcedure..................................12
Flushing.............................................................12
StartthePump...................................................12
StandardOperationFlushing...............................13
CheckTheRatio.................................................13
Maintenance......................................................14
WetCupMaintenance..................................14
BearingMaintenance...................................14
AirLubricationMaintenance..........................15
Troubleshooting..................................................16
LowSecondaryPumpPressure....................16
Repair................................................................19
DisconnecttheDisplacementPump..............19
ReconnecttheDisplacementPump...............20
DisconnecttheAirMotor..............................20
ReconnecttheAirMotor...............................20
ReplacetheBearings...................................21
Parts..................................................................22
Dimensions........................................................23
TechnicalSpeci󰘰cations......................................24
Notes...............................................................25
GracoStandardWarranty....................................26
23A3092A

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand
explosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Neversprayor󰘱ushsolventathighpressure.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareanti-staticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismay
looklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Getimmediate immediate immediatesurgical surgical surgical
treatment. treatment.
treatment.
•Donotspraywithouttipguardandtriggerguardinstalled.
•Engagetriggerlockwhennotspraying.
•Donotpointgunatanyoneoratanypartofthebody.
•Donotputyourhandoverthespraytip.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopsprayingandbeforecleaning,checking,
orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
3A3092A3

Warnings
WARNING WARNING
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestSafetyDataSheet(SDS)fromdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinch,cutoramputate󰘰ngersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicing
equipment,followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnectallpowersources.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
43A3092A

Warnings
WARNING WARNING
WARNING
SPLATTER SPLATTER
SPLATTERHAZARD HAZARD HAZARD
Hotortoxic󰘱uidcancauseseriousinjuryifsplashedintheeyesoronskin.Duringblowoffof
platen,splattermayoccur.
•Useminimumairpressurewhenremovingplatenfromdrum.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Protectiveequipment
includesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
3A3092A5

Models
Models Models
Models
Thefollowingchartgivesspeci󰘰cationsfortheHydra-CatH.P.pumps,usingNo.10weightoil.Thevolumetric
ratioisexpressedastheproportionofthevolumeof󰘱uidoftheprimarypumpcomparedtothevolumeof
󰘱uidofthesecondarypump.
Ratio Ratio
RatioAt At
AtMinimum Minimum MinimumRatio Ratio RatioSetting Setting SettingAt At AtMaximum Maximum MaximumRatio Ratio RatioSetting Setting SettingLower Lower
LowerID ID ID
Stall Stall
StallStall Stall StallOutput Output OutputOutput Output OutputStall Stall StallStall Stall StallOutput Output OutputOutput Output OutputMaster Master
MasterSlave Slave
Slave
Air Air
AirMotor Motor MotorAssem- Assem- Assem-
bly bly
blyPart Part Part
No. No.
No.Min Min
MinMax Max Max
PSI PSI
PSIBar Bar
BarGPM GPM
GPMLPM LPM
LPMPSI PSI
PSIBar Bar
BarGPM GPM
GPMLPM LPM
LPMDF DF DFDF DF DF
Xtreme
XL
9654811.504.5053333683.814.472735022.810.696
Xtreme
XL
9654792.006.0044443074.617.357143943.613.4126
Note:AllOutputPressuresLimitedTo5000PSIByIntegralPressureReliefValves
Note:Pressureoutputscalculatedat100PSIAirPressure
Note:Volumeoutputscalculatedat40cyclesperminute.
Approvals Approvals
Approvals
II 2 G c 230°C (T2)
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualDescription Description Description
334644XtremeXLAirMotor
311762XtremeLower
308547PressureReliefValve
63A3092A

Installation
Installation Installation
Installation
Location Location
Location
Sittheproportionerona󰘱at󰘱oorsurface.
Connect Connect
Connectthe the theFluid Fluid FluidSupply Supply SupplyLines Lines Lines
1.Connectthegrounded󰘱uidhosestothepump
inlet󰘰ttings(P,R).Iftheunitwillbepressure
fedfromseparatesupplyunits,installa󰘱uid
pressuregaugeateachinlet.
Note
Thepressurized󰘱uidsuppliesmust
notexceed1/4oftheoperating󰘱uid
pressureofthepump.Pressureabove
thatlevelwillfeedrightthroughthepump
andimproperrationingwillresult.
Connect Connect
Connectthe the theFluid Fluid FluidOutput Output OutputLines Lines Lines
1.Connectelectronicallyconductive󰘱uidhosesto
thepumpoutlet󰘰ttings.Tightenallofthe󰘰ttings.
Figure1
Key: Key:
Key:
ABleedTypeMainAirValve
BAirRegulator
CPressureReliefValve
DMixManifold
EAirSupplyLine
FAirLineFilter
GAirShutoffValve
HAirLineLubricator
JBaseSupplyPump
KCatalystSupplyPressurePot
LSolventSupplyPump
MMixManifoldFlushInlet
NStaticMixer
PPrimaryPumpInlet(Base)
RSecondaryPumpInlet(Catalyst)
SRatioAdjustmentScrew
TSprayGun
URatioIndicatorPlate
VRatioIndicatorPin
3A3092A7

Grounding
System System
SystemAccessories Accessories Accessories
Ableed-typemasterairvalve(A)isrequiredinyour
systemtorelievetheairtrappedbetweenthevalve
andthepumpafterthepumpisshutoff.Trappedair
cancausethepumptocycleunexpectedly,resulting
inpossibleseriousinjury,includingamputation.
Note
Toensurethemaximumpumpperformance
andsafety,besurethatalltheaccessories
usedareproperlysizedtomeetyoursystem
requirementsandthepressurelimitsofthe
pump.UseonlygenuineGracopartsand
accessories.
Intheairline,installanair󰘰lter(F)toremove
harmfuldirtandmoisturefromthecompressedair
supply.Installanairlinelubricator(H)downstream
fromtheair󰘰lter,theairregulator(B)andthe
bleed-typemasterairvalve(A).Alubricatorwill
provideautomaticlubricationtotheairmotor.
Connect Connect
Connectthe the theAir Air AirSupply Supply SupplyLine Line Line
1.Connectanelectricallyconductiveairsupply
hosetothe3/4”npt(f)portoftheairregulator(B).
Openthebleed-typemasterairvalve(A)and,
usingthepressuregauge,settheairregulator
(B)tothedesiredpressure.
Pressure Pressure
PressureRelief Relief ReliefValve Valve Valve
Allcomponentshaveratedworkingpressuresof
5000psi(345bar)orgreater.Formoreinformation
aboutthepressurereliefvalve,seeinstruction
manual308547.
Grounding Grounding
Grounding
Theequipmentmustbegroundedtoreducetherisk
ofstaticsparking.Staticsparkingcancausefumes
toigniteorexplode.Groundingprovidesanescape
wirefortheelectriccurrent.
Pump: SeeXLAirMotorinstructionmanualfor
completegroundinginstructions.
Airand󰘱uidhoses: Useonlyelectricallyconductive
hoseswithamaximumof500feet(150m)combined
hoselengthtoensuregroundingcontinuity.
Aircompressor: Followtheaircompressor
manufacturer’srecommendations.
Spraygunordispensingvalve: Obtaingrounding
throughconnectiontoaproperlygrounded󰘱uidhose
andpump.
Fluidsupplycontainer: followlocalcode.
Objectbeingsprayed: followlocalcode.
Allsolventpailsusedwhen󰘱ushing: Accordingto
localcode.Useonlyconductivemetalpailswhichare
conductive,placedonagroundedsurface.Donot
placethepailonanon-conductivesurface,suchas
paperorcardboard,whichinterruptsthegrounding
continuity.
Tomaintaingroundingcontinuitywhen󰘱ushingor
relievingpressure: Holdametalpartofthegunor
dispensingvalve󰘰rmlytothesideofagrounded
metalpail,thentriggerthegun.
83A3092A

AdjustRatio
Adjust Adjust
AdjustRatio Ratio Ratio
UnderstandingthetermsusedwiththeHydra–Cat Hydra–Cat
Hydra–Cat
(H.P.) (H.P.)
(H.P.)System System System,howitfunctions,andhowto󰘰ndand
setthecorrectratios ratios
ratiosforyourapplicationisthekeyto
easier,moreversatileoperationofyourproportional
system.
Besuretoreadandunderstandthefollowing
informationbeforeoperatingtheequipment.
Table Table
Table1 1 1Terms Terms Terms
Term Term
TermDe󰘰nition De󰘰nition
De󰘰nition
RatioRatio Ratio
Ratioreferstothe
simultaneousoutput
ofacertainvolumeof
󰘱uidbytheprimary primary
primaryand
secondary secondary
secondarypumps pumps pumps.
PrimaryPump(A)Theprimary primary
primarypump pump pump(A) (A) (A)
isdirectlyunderthe
air air
airmotor motor motor(H) (H) (H);itusually
pumpsthebase base
base󰘱uid.
SecondaryPump(B)Thesecondary secondary
secondarypump pump pump
(B) (B)
(B)isontheopposite
endofthelever lever
leverarm arm arm
(E); (E);
(E);itusuallypumpsthe
catalyst catalyst
catalyst.Theratioofthe
secondarypump(s)can
bechangedbyadjusting
theratio ratio
ratioadjustment adjustment adjustment
screw screw
screw(C). (C). (C).
Therearethreemainstepswhenapplyingtheuse
ofratios:
1.Determinetheratiothatisrequired,
2.Calculatetheratiosetting.
3.SettheratioontheHydra-CatH.P.system.
Figure2
APrimaryPump
BSecondaryPump
CRatioAdjustmentScrew
DWetCups
EFulcrumandArm
FPrimaryPumpOutput
GSecondaryPumpOutput
HAirMotor
JAirInput
KBleedTypeMasterAirValve
3A3092A9

AdjustRatio
Determine Determine
Determinethe the theRatio Ratio Ratio
Settheratiobasedonyoursituation.If:
•The The
The󰘱uids 󰘱uids 󰘱uidsare are aresupplied supplied suppliedat at ata a aready–to–spray ready–to–spray ready–to–spray
viscosity viscosity
viscosity,simplysettheratioasexplainedunder
AdjustingtheRatio,page11.
•The The
The󰘱uids 󰘱uids 󰘱uidsare are areNOT NOT NOTsupplied supplied suppliedat at atready–to–spray ready–to–spray ready–to–spray
viscosity viscosity
viscosity,theratiomustbedeterminedafterthe
reducerisaddedtothebase,asinstructedin
Procedure Procedure
Procedure1 1 1,below.
Note
Evaporationofthereducerinthebase
causeschangesintheratio.Toprevent
evaporation,storethebaseinaclosed
container.
Note
Somereducershaveverylittleabilityto
lubricateandmanycausesealstodryout.
Toprolongtheseallife,besureyourpump
sealsarecompatiblewiththebase’sreducer.
ContactyourGracorepresentativeforthe
correctsealstouse.
Procedure Procedure
Procedure1: 1: 1:Add Add AddReducer Reducer Reducerto to tothe the the
Base Base
Base
Whenaddingthereducertothebasebefore
proportioningwiththeHydra–Catsystem,determine
theratioofthebase/reducermixturetothecatalystin
ordertosettheproperratio.
Example:
Theinstructionsonthecansay“Mix5partsbaseto
1partcatalyst.Thenreduce3partsofthismixture
to1partreducer.”
1.Addtheparts parts
partsof of ofthe the thebase base baseand and andcatalyst catalyst catalystto󰘰ndthe
parts parts
partsmixture mixture mixture.
5partsbase
+1partscatalyst
6partsmixture
2.Thenextstatementonthecansays,“Reduce3
partsofthemixture.”Sodividetheparts parts
partsof of ofthe the the
mixture mixture
mixtureby3 3 3parts parts partsto to toreduce reduce reduceto󰘰ndtheparts parts parts
reducer reducer
reducer.
6partsmixture
/3partstoreduce
2partsreducer
3.Todeterminetheratioofthesecondarypump,
addtheappropriateparts parts
partsof of ofbase base baseand and andreducer reducer reducerto
󰘰ndtheparts parts
partscombined combined combinedbase/reducer base/reducer base/reducer.
5partsbase
+2partsreducer
7partscombinedbase/reducerto1 1
1
partcatalyst
Theratioofthepumpis7:1.
103A3092A