Graco 965478, 965466, 965477, 965481, 965479 User Manual

INSTRUCTIONS

ying

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

684025

Revision E

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

WARNING

MOVING PARTS HAZARD

Relieve fluid and air pressure to unit before servicin removed. Follow pressure relief procedure on page 11.

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 var used, includin potential dan individual components or their resultant mixtures. Graco assumes no responsibilit claims for bodil components.

unit. Do not operate with panels

WARNING

chemical reactions, the buyer and user of this equipment should determine all factors relating to the fluids

any of the potential hazards involved. Particular inquiry and investigation should be made into

ers relating to toxic fumes, fires, explosions, reaction times, and exposure of human beings to the

for loss, damage, expense or

injury or property damage, direct or consequential, arising from the use of such chemical

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441



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

2 684025

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

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.

WARNING

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

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 pumped.

valve used to spray or dispense the fluid bein

PLURAL COMPONENT FLUID HAZARD

Before usin fluids used, includin 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 from the use of such chemical components.

MOVING PARTS HAZARD

Movin

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.

this equipment, read the fluid manufacturer’s warnings and determine all facts relating to the

any of the potential hazards relating to toxic fumes, fires, explosions, reaction times,

e, expense or claims for personal injury or property damage, direct or consequential, arisin

parts, such as the air motor piston and the secondary pump lever and connecting rod area, can

684025 3

INSTRUCTION

g g

WARNING

FIRE AND EXPLOSION HAZARD

Improper

• 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.

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in

• 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 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

The lever amplification or the secondary pump enables very hi 5000 psi workin 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

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 bends near the couplings.

• Comply with all applicable local, state, and national fire, electrical, and safety regulations.

rounding, poor ventilation, open flames, or sparks can cause a hazardous condition and result in

fire or explosion and serious injury.

serious injury.

e, call your Graco

s printed on the pressure relief valve.

h fluid pressures to be achieved. A

pressure range relief valve is required on both cylinders to limit the fluid pressure. Do

es, moving parts, and hot surfaces. Do not

uards on both ends to protect them from rupture caused by kinks or

4 684025

WARNING

INJECTION HAZARD

Spray from the spray extremely serious injury, includin 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).

un, hose leaks or ruptured components can inject fluid into your body and cause

the need for amputation. Splashing fluid in the eyes or on the skin can

684025 5

Specifications of Hydra–Cat H.P. Pumps

96548

5333

368

3.8

696

9654792.00

6.00

3943.613

965

3.00

38032623.0

57043932.0

9654781.504.50

3.8

862.810.696

965466

3.00

9.00190

0228

The following chart gives specifications for the Hydra-Cat H.P. pumps, usin

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.

Ratio At Minimum Ratio Settin

Air Motor AssemblyMin Max Stall StallOutputOutput Stall Stall

Part No. PSI Bar GPM LPM PSI Bar GPM LPM DF DF

Premier

Kin

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.

11.504.

477 1.

4444

42 21

1131

74.617.

.1 23.

For example, Model 965477 has a minimum volumetric ratio of 1:1. At this settin pumps combined will deliver an output of 3.0 maximum volumetric ratio for Model 965477 is 3:1 and the combined output at that setting is 2.0 gpm.

At Maximum Ratio Settin

14.4 727

714

11.

14.4 41482

22.810.

2157

the primary and secondary

pm. The

Lower ID

utputOutput Master Slave

.4 12

7.7

.1 19.2 1

Installation

The Typical Installation shown is only a guide to setting up the complete Hydra-Cat H.P. system. For assistance in

ning a system to suit your particular needs, contact

desi 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 operatin that level will feed ri rationing will result.

fluid pressure of the pump. Pressure above

ht through the pump and improper

Connect the Fluid Output Lines

Connect electronically conductive fluid hoses to the pump outlet fittings. Tighten all of the fittings.

Fig. 1

6 684025

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

enuine Graco parts and

accessories.

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

ulator (B) to the desired pressure. See the Typical

air re Installation and the Parts Drawing.

Pressure Relief Valve

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

ulator (B) and the bleed-type master air valve (A). A

re lubricator will provide automatic lubrication to the air motor.

All components have rated working pressures of 5000 psi (345 bar) or

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 possible serious injury, including amputation.

the pressure gauge, set the

684025 7

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