Graco 684025e User's Manual
Contents
1. 1 Add the parts of the base and catalyst to find the parts 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 6 parts mixture 3 parts to reduce 2 parts 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 5 parts base 2 parts reducer 7 parts combined base reducer to 1 part catalyst The ratio of the pump is 7 1 Relationship Between the Secondary Pumps Primary and Moving the fulcrum point away from the primary pump reduces the secondary stroke length reducing its fluid output Moving the fulcrum point closer to the primary pump increases the secondary stroke length increasing its fluid output Fig 5 shows the relationship between the primary pump and the secondary pump Adjusting the Ratio See Fig 2 Use a wrench to rotate the ratio adjustment screw S Rotating the screw clockwise will increase the ratio Rotating the screw counterclockwise will decrease the ratio The indicator pin V will move along 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 Minimum Ratio 2 Maximum Ratio 1 3 5 parts base 12. 22 Symbols Caution Symbol CAUTION Warning Symbol WARNING 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 Definition 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 instructions of Terms 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 dispensing valve used to spray or dispense the fluid being pumped WARNING PLURAL COMPONENT FLUID HAZARD Before using this equipment read the fluid manufacturers warnings and determine all facts relating to the fluids used including any of the potential hazards relating to toxic fume
3. 40 C 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 spring guards 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 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 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 a
4. slowly at first to ensure proper operation Bearing Inset Dimensions A Height 66 0 inch 1676 mm B Length 31 5 inch 800 mm C eu H 33 0 inch 838 mm RE lgl 3 4 npt f E Fluid Inlete eenen Two 2 npt f G Fluid Outlet Two 1 2 npt f H Relief Valve Outlets ceeee Two 1 4 npt m Net Weight 700 pounds 320 kg Premier Air Consumption At 40 PSI 2 8 bar At 70 PSI 4 9 bar At 100 PSI 7 0 bar At cycles M min C M min Miimin per min King Air Consumption At 40 PSI 2 8 bar At 70 PSI 4 9 bar At 100 PSI 7 0 bar At cycles CFM M min M min M min per min 684025 19 NOTES 20 684025 Technical Data Air motor effective diameter cceceecceceseeceeeeseneeseneeeeseneaneesesaneeseseeseseeneenenenaes Premier 12 64 321 mm EE King 10 00 254 mm Ligue ege 4 75 120 mm Operating air pressure range 20 to 100 psi 1 4 to 7 bar Recommended PUMP speed 40 cycles per minute maximum Maximum fluid inlet pressure oe eececeeeeeeeeeeeneeeeeeeeeeeeeeaeeeetenaeeeeeeeeeeenaes 25 of Output or 1000 psi max Maximum pump operating Temperature 180 F 82 C Wetted parts Carbon Steel Models Primary and secondary displacement pumps ssesseeeeee Carbon Steel Chrome Steel Alloy Steel Chrome Zinc and Nickel Plating 550 and 17 4 PH Grades of Stainless Steel Ductile Iron Tungsten Carbide PTFE Glass Filled PTFE L
5. 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 guide to setting up the complete Hydra Cat H P system For assistance in designing 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 grounded fluid hoses to the pump inlet fittings 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 operating fluid pressure of the pump Pressure above that level will feed right through the pump and improper rationing will result 6 684025 Connect the Fluid Output Lines Connect electronically conductive fluid hoses to the pump outlet fittings Tighten all of the fittings Fig 1 e KEY HE SS Bleeder Type J Main Air Valve E Air Regulator A eil Pressure Relief Ei Valve f S Mix Manifold l Air Supply Line ama Air Line Filter S Air Shutoff Valve Air Line Lubricator Base Supply Pump BASE Catalyst Supply Pressure Pot ACIOTMMO OW gt CATALYS
6. Fluid supply container according to your local code Object being sprayed according to local code All solvent pails used when flushing according to local code Use only metal pails which are conductive placed on a positively grounded surface Do not place the pail on a non conductive surface such as paper or cardboard which interrupts the grounding continuity To maintain grounding continuity when flushing or relieving pressure always hold a metal part of the gun or dispensing valve firmly to the side of a grounded metal pail then trigger the gun 0720 Ratio Adjustment Understanding the terms used with the Hydra Cat HP 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 Key D Wet Cups E Fulcrum and Arm F Primary Pump Output G Secondary Pump Output A Primary Pump B Secondary Pump C Ratio Adjustment Screw 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 F
7. lightweight oil at the factory Before operating the pump thoroughly flush the Hydra Cat H P to prevent contamination of your fluids NOTE Flush the mixer hose and gun often enough to prevent fluid from reacting or curing in them Contact your fluid manufacturer for the effective pot life of the fluid you are using 1 Put the pump intake hoses into a 5 gallon 20 liter container of a compatible solvent Refer to the fluid manufacturer s recommendations 2 Start the pump as explained below 3 Do not install a spray tip yet Hold a metal part of the gun firmly to the side of a grounded metal pail Using the lowest possible air pressure to the air motor that will activate the pump trigger the gun into the pail 4 When clean solvent comes from the spray gun release the trigger and carefully check all connections in the system for leaks 5 Take the hoses out of the solvent and trigger the gun until all the solvent has been pumped out of the hoses Immediately turn off the bleeder type master air valve Start the Pump 1 Close the bleed type master air valve and turn the air regulator knob all the way out counterclockwise 2 Turn on the main air supply 3 With the mixer manifold handle in the open position trigger the gun slowly open the bleed type master air valve and turn the air regulator knob clockwise until the pump starts 4 Allow the pump to cycle slowly until all the air is pushed out of the lin
8. not within 20 of your normal operating pressure follow the flushing procedure on page 11 then take a sample again If your sample ratio is incorrect there is a problem with the sampling valves ratio setting or pump operation Check the ratio setting or service the sampling valves or pump Slightly open the sampling valve on the secondary pump side Slightly open the sampling valve on the primary pump side This will prevent pressure from building up on the secondary pump causing the relief valve to open 5 Place a grounded waste container under the sampling valve Pump Lubrication Bearings Wet Cups Many of the bearing surfaces on the proportioner are permanently lubricated or are self lubricating There are Each of the fluid cylinders has a wet cup 18 at the top four main bearings 21 on the lever arm that must be that must be kept lubricated See figure 6 The wet cups lubricated on a regular interval The lubrication interval should be inspected and filled on a weekly basis or is every six months in single shift operation To lubricate more frequently if found to be dry To inspect the wet the bearings follow the pressure relief procedure on cups follow the pressure relief procedure on page 11 page 11 WARNING WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 11 To reduce the risk of serious injury whenever you are instruc
9. parts catalyst 6 parts mixture Position 1 Soke ength Primary Pump and Air Motor el Fig 5 10 684025 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 e are instructed to relieve the pressure stop spraying check or service any of the system equipment or install or clean the spray tips Pressure Relief Procedure 1 a F A Lock the spray gun s trigger safety Shut off ALL fluid supplies to the pump Close the bleed type master air valve Unlock the spray gun s trigger safety Hold a metal part of the spray gun firmly to the side of a grounded metal pail Trigger the spray gun into the pail to relieve pressure Lock the spray gun s trigger safety Open the sampling valves having a container ready to catch the drainage If you suspect that the spray tip or nozzle or the hose is completely clogged or that pressure has not been fully relieved after following the steps above follow this procedure Very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually then loosen completely Now clear the obstruction System Flushing The pumps were tested with
10. person to handle A lift ring is provided on the motor for this purpose 5 Note the relative position of the air motors air connection to the frame The air motor must be returned to its original orientation 6 Using an adjustable wrench or hammer and punch unscrew the coupling nut 9 from the rod adapter 13 Do not lose or drop the coupling collars 12 See Fig 6 7 Hold the tie rod flats with a wrench to keep the rods from turning Unscrew the nuts 8 from the tie rods 6 Carefully remove the air motor 2 from the frame 8 Refer to the separate manual supplied for air motor service Be sure to look at the model number stamped on the air motor and use the appropriate manual for service and reference Reconnecting the Air Motor 1 If the connecting rod has been removed from the Air Motor Stud as a part of servicing be sure to use thread adhesive when reinstalling the connecting rod on to the Air Motor Stud 2 Make sure the coupling nut 9 and the coupling collars 12 are in place on the rod adapter 13 3 Use an overhead hoist to position the air motor on the frame in the same orientation as noted in step 5 of disconnecting the air motor see the CAUTION in the removal procedure above Position the air motor 2 on the tie rods 6 5 Screw the nuts 8 onto the tie rods 6 and torque to 81 89 N m 60 66 ft lb 6 Screw the coupling nut 9 onto the rod adapter 13 loosely Hold the rod adapt
11. with a wrench to keep it from turning Use an adjustable wrench to tighten the coupling nut Torque to 196 210 N m ft lb 7 Fill the wet cup 18 1 3 full with Graco Throat Seal Lubricant or compatible solvent 8 Reconnect all hoses 9 Replace the two guards 15 and the thumb screws 14 from the sides of the proportioner 10 Turn on the air supply Follow the procedure for starting the pump on page 11 Run the pump slowly at first to ensure proper operation WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 11 11 Before returning the pump to production relieve the pressure and re torque the packing nut 2 to 136 149 N m 100 110 ft lb The must be performed after the pump has been cycled a number of times Disconnecting the Air Motor 1 Relieve the pressure 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 turned off disconnect the air hose from the air motor 3 Remove the thumb screws 14 and the two guards 15 from the sides of the proportioner 4 Disconnect the air motor 2 from the frame 5 as follows CAUTION 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
12. 25 15 Service Required Tools Set of large adjustable wrenches e Set of metric sockets or wrenches e Large pipe wrench e Torque wrench e Rubber mallet e Flat end punch WARNING To reduce the risk of serious injury or amputation carefully follow all instructions listed below In addition be sure that the pressure relief procedure has been completed and that the main bleeder type air valve has been turned off and locked out before removing ANY guards or covers from the proportioner 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 displacement pump being removed Each displacement pump must be returned to its original position and orientation Be sure to use two people when lifting moving or disconnecting the pump This pump is too heavy for one person Be sure to support the displacement pump while it is being disconnected to prevent it from falling and causing injury or property damage Do this by securely bracing the pump or by having at least two people hold it while another disconnects it Disconnecting the Displacement Pump s 1 Flush the System Follow the procedure on page 11 2 Relieve the pressure WARNING To red
13. INSTRUCTIONS oe 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 Gi WARNING MOVING PARTS HAZARD Relieve fluid and air pressure to unit before servicing unit Do not operate with panels removed Follow pressure relief procedure on page 11 WARNING Graco Inc does not manufacture or supply any 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 varying chemical reactions the buyer and user of this equipment should determine all factors relating to the fluids used including any of the potential hazards involved Particular inquiry and investigation should be made into potential dangers 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 property damage direct or consequential arising from the use of such chemical components GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 1998 Graco Inc Warnings Table of Contents Specification of Hyd
14. T rc Solvent Supply Pump Mix Manifold Flush Inlet Static Mixer Primary Pump Inlet Secondary Pump Inlet Ratio Adjustment Screw Spray Gun Ratio Indicator Plate Ratio Indicator Pin lt CcCH wo DIZ Z Fig 2 Typical Installation System Accessories 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 genuine 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 regulator B and the bleed type master air valve A A lubricator will provide automatic lubrication to the air motor 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 resulting in possible serious injury including amputation A ad A di Connect the Air Supply Line 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 using the pressure gauge set the air regulator B to the desired pressure See the Typical Installation and the Par
15. each of warranty must be brought within two 2 years of the date of sale EQUIPMENT NOT COVERED BY GRACO WARRANTY Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose with respect to accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motor switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties Graco Information FOR TECHNICAL ASSISTANCE contact your Graco distributor or call one of the following numbers 1 800 367 4023 612 623 6921 612 378 3505 Fax Sales Offices Minneapolis Detroit International Offices Belgium Korea Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 684025 Revised 06 2003 22 684025
16. eather Stainless Steel Models Primary and secondary displacement pumps 316 440 and 17 4 PH Grades of Stainless Steel Tungsten Carbide PTFE Glass Filled PTFE Leather All Models ellen Le Nylon Zinc plated steel couplings Pressure relief valves ccccccccsssssseceeeeeeeeeeeessseeeeeeeeeees 304 Stainless Steel Graphite filled PTFE Tungsten carbide Nickel binder Premier Noise level at 90 psi 6 3 bar inlet air and at 40 com maximum Jos 86 dB A King Noise level at 90 psi 6 3 bar inlet air and 15 com maximum load 90 5 dB A Pressure 97 7 dB A Power 684025 21 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 This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non G
17. er flats with a wrench to keep it from turning Use an adjustable wrench to tighten the coupling nut Torque to 196 210 N m ft lb 7 Reconnect the air hose 8 Replace the two guards 15 and the thumb screws 14 onto the sides of the proportioner 9 Turn on the air supply Follow the procedure for starting the pump on page 11 Run the pump slowly at first to ensure proper operation 684025 17 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 Do not remove the sensor but carefully set the cover to the side without straining or damaging the sensor or cable The 4 four main bearings 21 are now exposed 3 Remove the thumb screws 14 and the two guards 15 from the sides of the proportioner 4 Using an adjustable wrench or hammer and punch unscrew the coupling nuts 10 11 12 from each of the rod adapters 13 on the two displacement pumps and the air motor Do not lose or drop the coupling collars 12 See Fig 6 5 The left rear bearing shaft has a magnet s
18. es Release the trigger The pump will stall against the pressure 5 The manifold handle controls fluid flow With the lever of the manifold in the open down position base and catalyst are supplied to the gun To stop the flow move the handle to the closed up position Standard Operating Flushing Use the solvent valves to flush contaminants and mixed fluids from the mixer manifold hose and spray gun Follow the procedure provided with the mix manifold assembly 684025 11 Checking the Ratio 6 Open the mixer manifold Use the sampling valves to Note The mix ratio must be checked at the normal DE EE EE EE pressures operating fluid pressure of the pump Most mixer manifolds provide a means for checking mix ratio 7 Close the mixer manifold Put the sampling that includes needle valves for adjusting the fluid containers under the sampling valves pressure during the test The following procedure is 8 Open the mixer manifold Check the ratio make sure an example of how to properly check the mix ratio the pressure is within 20 of your normal operating 1 Open the mixer manifold and trigger your spray gun pressure Close the mixer manifold when enough fluid has been dispensed into the sampling 2 Set your operating pressure After determining the sontadihers operating pressure release the spray gun trigger and engage the safety latch 3 Close the mixer manifold inlet valves NOTE If the pressure readings are
19. ig 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 H Air Motor Air Input J Bleed Type Master Air Valve Fig 4 684025 9 Determine the Ratio Set the ratio based on your situation If e The fluids are supplied at a ready to spray viscosity simply set the ratio as explained under Adjusting the Ratio e 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 NOTE Some reducers have very little ability to lubricate and many cause seals to dry out To prolong 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 adding the reducer to the base before proportioning 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
20. or Air pressure or air Increase air pressure Check air compressor and air supply filters stops while running volume is too low 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 Check the gun fluid hoses mix manifold static mixer fluid filters hoses are closed or regulators valves and other fluid line components for blockages restricted and restrictions If this is a new system be sure that the fluid components have been sized properly The air motor is Service the air motor See servicing the Air Motor on page 17 worn or damaged The displacement See troubleshooting techniques below to isolate the problem cylinder s is cylinder See Service the cylinders on page 16 damaged or has The fluid pressure Air volume is too Verify that air pressure at the air motor inlet is not dropping during bounces significantly pump changeover Check air compressor and air supply filters gt 500 psi while pump is regulator lubricator valves and other components for blockages and running restrictions If this is a new system be sure that air supply components have been sized properly 1 NPT hoses fittings and accessories are required to provide the necessary air volume Feed pump Reduce feed pump pressure Feed pump pressures must be less pressure is too than 25 of proportioner output
21. pressure The displacement See troubleshooting techniques below to isolate the problem cylinder s check cylinder See Service the cylinders on page 16 valves are not Mix ratio test is Mix ratio test was Perform ratio test again following ratio test procedure on page 12 significantly different from not performed at the mix ratio setting the normal operating pressure of the Running out of one Check and refill material reservoirs Repeat the test after the air has material been removed from the system The displacement See troubleshooting techniques below to isolate the problem cylinder s are worn cylinder s See Service the cylinders on page 16 or the check valves are not seating Spray output is spitting Running out of one Check and refill material reservoirs Remember that once air is in material the fluid system it may take a while for all of it to escape Siphon hoses are Tighten and seal all siphon fittings on proportioning pump and feed leaking in air pumps A squeaking or knocking The bearings are Lubricate the bearings or replace them if required See service the noise is heard dry or worn bearings on page 18 The proportioner speeds Running out of one Check and refill material reservoirs up or runs erraticall material The cylinders are See troubleshooting techniques below to isolate the problem worn or damaged cylinder s See Service the cylinders on page 16 6840
22. ra Cat H P Pumpen Installation Ratio Adjustment 2 Connect the Fluid Supply Line Connect the Fluid Output Lines s System Accessories eeeeeeeeeeeeeeeeeee erreren ereen Connect the Air Supply Line sseseeeseeeseeeeeeeeen Pressure Relief Valve A Electrical Groundimg eege endothe eege SE haa tere cred Determine the Hato 10 Relationship Between the Primary and Secondary PUMPS sssseesseeseesereereererresrerrrerneee 10 Adjusting the Ratio Setting ccceeeseeeeeeeeees 10 684025 p tatlon eiiiai deviance nee 11 Pressure Relief Procedure AA 11 System FIUSHING siss metsien i diiernna wea ikhas 11 Start th PUMP ureien raean iie tee ENEE 11 Standard Operating Flushing 11 Checking the Ratio c ccecceeeseeeeseeeseeeeeeeeeeeeeees 12 Maintenance cacr iiae a ERA 12 UE E 12 Bearings sas eects ects ei ed EEN eeben 12 Air Lubrication cecene e 13 Troubleshooting ein r a e TE e E E T 14 Troubleshooting Techniques s e 14 Troubleshooting Chart 15 Eug edel 16 Required Tools 0 0 0 eeeceeeeeseeeeeeneeeeeeeneeeeeeseeeeneaes 16 Disconnecting the Displacement Pump 16 Reconnecting the Displacement Pump 17 Disconnecting the Air Motor 17 Reconnecting the Air Motor A 17 Replacing the Bearmnge 18 Blue 19 Air Copsumption tees eeeeeeeeaeeteteeeteneeteaeeeee 19 Technical Data A 21 Graco Information c ccceeeeeeeeeeeeeeeeneeeeeeeeeeeesseeeeaes 22 Graco Standard Warranty s
23. raco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility with Graco equipment of structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claim If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may includes the costs of parts labor and transportation DISCLAIMERS AND LIMITATIONS The terms of this warranty constitute purchaser s sole and exclusive remedy and are in lieu of any other warranties express or implied including warranty of merchantability or warranty of fitness for a particular purpose and of any non contractual liabilities including production liabilities based on negligence or strict liability Every form of liability for direct special or consequential damages or loss is expressly excluded and denied In no case shall Graco s liability exceed the amount of the purchase price Any action for br
24. re 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 180 F 82 C or below 40 F 40 C 684025 5 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 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 gom The maximum volumetric ratio for Model 965477 is 3 1 and the combined output at that setting is 2 0 gpm At Minimum Ratio Setting Sep 965481 a a EE EE EE Heft ors 14 4 4148 286 106 6 Kina 965478 210 as kec a Wana eal lia oa EE aa a ee ae PEETA At Maximum Ratio Setting a Part No FA lt a Note All Output Pressures Limited To 5000 PSI By Integral Pressure Relief Valves Note Pressure outputs calculated at 100 PSI
25. rt Number 110293 or equivalent details Replace the covers 17 and the bolts 16 after greasing and before starting the machine The covers 17 are safety guards and must be in place when the proportioner is in operation KEY 1 BLEEDER TYPE MAIN AIR VALVE 13 ROD ADAPTER 2 AIR MOTOR 14 THUMB SCREWS 3 PRIMARY CYLINDER 15 GUARDS 4 SECONDARY CYLINDER 16 HEX BOLTS 5 FRAME 17 COVERS 6 AIR MOTOR TIE RODS 18 WET CUPS 7 FLUID CYLINDER TIE RODS 19 PACKING NUTS 8 TIE ROD NUTS 20 PACKING NUT WRENCH 9 CONNECTING ROD NUT AIR MOTOR 21 MAIN BEARINGS 10 CONNECTING ROD NUT PRIMARY 22 SNAP RING 11 CONNECTING ROD NUT SECONDARY 12 COUPLING COLLARS Fig 6 FLUID OUTLET PRIMARY FLUID OUTLET SECONDARY 684025 13 Troubleshooting Troubleshooting Techniques 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 For example if the secondary pump pressure as read on the gauge is low and sluggish during the pump changeover The most likely problem is a binding primary pump To isolate the problem 1 Relieve the pressure 2 With the sampling valves still open set the air supply regulator to the lowest setting and open the bleed type main air valve 1 Refer to figure 6 Increase the regula
26. s 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 damage expense or claims for personal injury or property damage direct or consequential arising from the use of such chemical components MOVING PARTS HAZARD Moving parts such as the air motor piston and the secondary pump lever and connecting rod area can pinch or amputate fingers m Tes e Do not operate the equipment with the guards removed e Keep your body and tools clear of any moving parts when starting or operating the equipment 684025 3 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 Do not t
27. ted to relieve pressure always follow the Pressure Relief Procedure on page 11 With the bleeder type main air valve 1 turned off remove the thumb screws 14 and the two guards 15 from the sides of the proportioner The wet cups 18 should be filled to 1 3 full with Graco Throat Seal Liquid TSL or compatible solvent With the bleeder type main air valve 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 packing nuts 19 are torqued at the factory and are The left rear cover may contain a sensor attached to a ready for operation If one becomes loose and there is cable Do not remove the sensor but carefully set the leaking from the throat packings relieve the pressure cover to the side without straining or damaging the then torque the nut to 136 149 N m 100 110 ft lb sensor or cable The four main bearings 21 are now using the supplied wrench 20 Do this whenever exposed Use the adapter 205532 provided to grease all necessary Do not over tighten the packing nut eee One or two squirts 2 3 cc will be 12 684025 Air Lubrication If your air supply Is very dry install an air line lubricator between the air regulator and the pump air motor for Make sure to use an Industrial Grade 1 Heavy Duty automatic lubrication Refer to the air motor manual for Extreme Pressure Lithium Soap Grease Graco Pa
28. tor setting until the pump just begins to move Notice the position of the secondary pump 11 Turn off the bleeder type main air valve 1 so that the secondary pump rod is at its lowest position when the pump stops WARNING To reduce the risk of a serious injury always follow the Pressure Relief Procedure on page 11 whenever you are instructed to relieve the pressure 3 With the main bleed type air valve 1 off remove the thumb screws 14 and guards 15 from each side of the proportioner 4 Unscrew the connecting rod nut 11 from the secondary pump Now you can verify the operation of the primary pump alone Reinstall the guards 15 on both sides of the proportioner Turn the main air valve 1 back on and carefully increase the air pressure 5 Using the sampling valves at the mixer manifold A Open and close the sampling valves and check for pump stalling on both the up and down strokes B Check for rapid gauge response during the pump changeover 6 When the operation of the primary side has been verified reconnect the connecting rod 11 of the secondary 7 With the sampling valves still open set the air supply regulator to the lowest setting and open the bleed type main air valve 1 Increase the regulator setting until the pump just begins to move Notice the position of the primary pump Turn off the bleeder type main air valve 1 so that the primary pump rod 10 is at its lowest position
29. ts Drawing Pressure Relief Valve All components have rated working pressures of 5000 psi 345 bar or greater For more information about the pressure relief valve see instruction manual 308547 684025 7 Electrical Grounding WARNING 4 FIRE AND EXPLOSION HAZARD d Static electricity is created by the high velocity 8 flow of fluid through the pump and hose If your system is not properly grounded sparking may occur and the system may become hazardous To reduce the risk of static sparking which can result in a fire or explosion and cause serious injury follow these recommendations for providing electrical continuity throughout your system Also read the WARNING section FIRE AND EXPLOSION HAZARD on page 4 Pump Loosen the grounding lug locknut A and washer Insert one end of a 12 ga 1 5 m2 minimum ground wire B into the slot in the lug C Tighten the locknut securely See Fig 3 Connect the other end of the ground wire to a true earth ground Order a Grounding Clamp P N 103538 and a Grounding Wire P N 208950 25 feet 7 6 m long 12 ga Air and fluid hoses Use only electrically conductive hoses with a maximum of 500 feet 150 m combined hose length to ensure grounding continuity Air compressor follow the air manufacturers recommendations compressor 684025 Fig 3 Spray gun or dispensing valve Obtain grounding through connection to a properly grounded fluid hose and pump
30. tuck on its end Remove the magnet and put it in a safe place Use a snap ring pliers to remove the four snap rings 22 from the shafts and remove the retaining washers 6 You should now be able to slide the bearings 21 off of the shaft ends 7 Replace the bearings only with identical Graco replacement parts Pack the bearings in Industrial Grade 1 Heavy Duty Extreme Pressure Lithium Soap Grease Graco Part Number 110293 or equivalent 22 A x r f Inject a rease Here E v Fig 7 18 684025 13 14 Re install the new bearings 21 onto the shafts Doing so may require slightly shifting the shaft assembly which may have dropped during bearing removal Re install the four retaining washers and their snap rings 22 Replace the magnet onto the end of the left rear bearing shaft Make sure the coupling nuts 10 11 12 and the coupling collars 12 are in place on all three rod adapters Screw all three 3 coupling nuts 10 11 12 onto the rod adapters 13 loosely Hold each rod adapters flats with a wrench to keep it from turning Use an adjustable wrench to tighten the coupling nuts Torque to 196 210 N m ft lb Replace the covers 17 and the bolts 16 Replace the two guards 15 and the thumb screws 14 onto the sides of the proportioner Turn on the air supply Follow the procedure for starting the pump on page 11 Run the pump
31. uce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 11 3 Disconnect the siphon hose and the fluid outlet hose 16 684025 7 Using an adjustable wrench or hammer and punch unscrew the coupling nut 10 11 from the rod adapter 13 Do not lose or drop the coupling collars 12 See Fig 6 8 Hold the tie rod flats with a wrench to keep the rods from turning Unscrew the nuts 8 from the tie rods 7 Carefully remove the displacement pump 3 from the frame 9 Refer to the separate manual supplied for displacement pump service Some models use two different displacement pumps Be sure to look at the model number and use the appropriate manual for service and reference Reconnecting the Displacement Pump 1 Make sure the coupling nut 10 11 and the coupling collars 12 are in place on the displacement rod See Fig 6 2 Use at least two people to hold the displacement pump while another reconnects it to the frame see the CAUTION in the removal procedure above 3 Position and orient the displacement pump 3 4 to the frame 5 as was noted in step 6 under Disconnecting the Displacement Pump 4 Position the displacement pump 3 4 on the tie rods 7 5 Screw the nuts 8 onto the tie rods 7 and torque to 81 89 N m 60 66 ft lb 6 Screw the coupling nut 10 onto the rod adapter 13 loosely Hold the rod adapter flats
32. urn 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 EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture malfunction or start unexpectedly and result in INSTRUCTIONS 4 684025 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 usage 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 ratings printed on the pressure relief valve The lever amplification or the secondary pump enables very high fluid pressures to be achieved A 5000 psi working pressure range 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 edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 180 F 82 C or below 40 F
33. when the pump stops 14 684025 8 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 Reinstall the guards 15 on both sides of the proportioner Turn the main air valve 1 back on and carefully increase the air pressure 10 Using the sampling valves at the mixer manifold A Open and close the sampling valves and check for pump stalling on both the up and down strokes B Check for rapid gauge response during the pump changeover 11 When the operation of the secondary side has been verified reconnect the connecting rod 10 of the primary pump WARNING Use very low air pressure to the air motor when troubleshooting the system This system can produce very high fluid pressure which can cause serious injury including injection splashing in the eyes or on the skin and injury from moving parts To reduce the risk of a serious injury always follow the Pressure Relief Procedure on page 11 if the problem you are checking does not require air WARNING To reduce the risk of injuring or amputating your hands fingers or other body parts never place your hands body or tools inside the safety panels for any reason while the unit is operating Troubleshooting Chart PROBLEM CAUSE SOLUTION System will not run
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