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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
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.

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

Summary of Contents for Hydra-Cat H.P. King

Page 1: ...ir 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 huma...

Page 2: ... 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 Pum...

Page 3: ...his 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 manufacturer s warnings and determine all facts relating to the fluids used including any of the potential hazards relating to toxic fumes fires explosions reaction times and exposure of human beings to the in...

Page 4: ...ts 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 ...

Page 5: ...gger 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 a...

Page 6: ...ng 965466 3 00 9 00 1901 131 6 1 23 0 2282 157 5 1 19 2 18 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 guide to setting up the complete Hydra Cat H P ...

Page 7: ...ilter 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 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 ...

Page 8: ... 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 8 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...

Page 9: ...rimary 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 settin...

Page 10: ...talyst to find the parts mixture 5 parts base 1 parts catalyst 6 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 ba...

Page 11: ...he side of a grounded metal pail Trigger the spray gun into the pail to relieve pressure 6 Lock the spray gun s trigger safety 7 Open the sampling valves having a container ready to catch the drainage 8 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 t...

Page 12: ...6 The wet cups should be inspected and filled on a weekly basis or more frequently if found to be dry To inspect the wet cups follow the pressure relief procedure on page 11 Bearings Many of the bearing surfaces on the proportioner are permanently lubricated or are self lubricating There are four main bearings 21 on the lever arm that must be lubricated on a regular interval The lubrication interv...

Page 13: ...tor between the air regulator and the pump air motor for automatic lubrication Refer to the air motor manual for details 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 CONNECT...

Page 14: ...isk of a serious injury always follow the Pressure Relief Procedure on page 11 whenever you are instructed to relieve the pressure 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 3 With the main bleed type air valve 1 off remove the thumb screws 14 and guards 15 from each side of the proporti...

Page 15: ...provide the necessary air volume Feed pump pressure is too high Reduce feed pump pressure Feed pump pressures must be less than 25 of proportioner output pressure The displacement cylinder s check valves are not seating See troubleshooting techniques below to isolate the problem cylinder See Service the cylinders on page 16 Mix ratio test is significantly different from the mix ratio setting Mix r...

Page 16: ...r 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 Re...

Page 17: ...l 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 co...

Page 18: ...se 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 8 Re install the new bearings ...

Page 19: ...13 0 36 20 0 56 26 0 74 5 25 0 71 40 1 13 52 1 48 10 38 1 07 60 1 69 78 2 22 15 50 1 42 80 2 26 104 2 95 20 63 1 78 100 2 82 130 3 69 25 75 2 13 120 3 39 156 4 43 30 88 2 49 140 3 95 183 5 17 35 100 2 84 160 4 52 209 5 91 40 King Air Consumption At 40 PSI 2 8 bar CFM M 3 min At 70 PSI 4 9 bar CFM M 3 min At 100 PSI 7 0 bar CFM M 3 min At cycles per min 8 0 23 13 0 36 15 0 43 5 16 0 45 25 0 72 31 0...

Page 20: ...20 684025 NOTES ...

Page 21: ...oy Steel Chrome Zinc and Nickel Plating 550 and 17 4 PH Grades of Stainless Steel Ductile Iron Tungsten Carbide PTFE Glass Filled PTFE Leather 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 Fluid hoses Nylon Zinc plated steel couplings Pressure relief valves 304 Stainless Steel...

Page 22: ...ser 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 includin...

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