Graco Hydra-Cat Xtreme XL, Instructions - Parts Manual

Page 1: ... ratio proportioner proportioner proportioner for for for applying applying applying high high high solids solids solids protective protective protective coatings coatings coatings Important Important Important Safety Safety Safety Instructions Instructions Instructions Read all warnings and instructions in this manual and in related manuals Save these instructions See Models page 6 PROVEN QUALITY...

Page 2: ...sting the Ratio 11 Pressure Relief Procedure 12 Flushing 12 Start the Pump 12 Standard Operation Flushing 13 Check The Ratio 13 Maintenance 14 Wet Cup Maintenance 14 Bearing Maintenance 14 Air Lubrication Maintenance 15 Troubleshooting 16 Low Secondary Pump Pressure 16 Repair 19 Disconnect the Displacement Pump 19 Reconnect the Displacement Pump 20 Disconnect the Air Motor 20 Reconnect the Air Mot...

Page 3: ...ug or unplug power cords or turn power or light switches on or off when flammable fumes are present Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail Do not use pail liners unless they are anti static or conductive Stop Stop Stop operation operation operation immediately immediately immediately if static sparking occurs or you feel a shock Do not use equipm...

Page 4: ...ations may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children an...

Page 5: ... drum PERSONAL PERSONAL PERSONAL PROTECTIVE PROTECTIVE PROTECTIVE EQUIPMENT EQUIPMENT EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns Protective equipment includes but is not limited to Protective eyewear and hearing protection Respirators protective clothing and gloves as rec...

Page 6: ...ter Master Master Slave Slave Slave Air Air Air Motor Motor Motor Assem Assem Assem bly bly bly Part Part Part No No No Min Min Min Max Max Max PSI PSI PSI Bar Bar Bar GPM GPM GPM LPM LPM LPM PSI PSI PSI Bar Bar Bar GPM GPM GPM LPM LPM LPM DF DF DF DF DF DF Xtreme XL 965481 1 50 4 50 5333 368 3 8 14 4 7273 502 2 8 10 6 9 6 Xtreme XL 965479 2 00 6 00 4444 307 4 6 17 3 5714 394 3 6 13 4 12 6 Note Al...

Page 7: ...l will feed right through the pump and improper rationing will result Connect Connect Connect the the the Fluid Fluid Fluid Output Output Output Lines Lines Lines 1 Connect electronically conductive fluid hoses to the pump outlet fittings Tighten all of the fittings Figure 1 Key Key Key A Bleed Type Main Air Valve B Air Regulator C Pressure Relief Valve D Mix Manifold E Air Supply Line F Air Line ...

Page 8: ...re Pressure Relief Relief Relief Valve Valve 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 Grounding Grounding Grounding The equipment must be grounded to reduce the risk of static sparking Static sparking can cause fumes to ignite or explode Grounding provides an escape wire for t...

Page 9: ...s Primary Pump A The primary primary primary pump pump pump A A A is directly under the air air air motor motor motor H H H it usually pumps the base base base fluid Secondary Pump B The secondary secondary secondary pump pump pump B B B is on the opposite end of the lever lever lever arm arm arm E E E it usually pumps the catalyst catalyst catalyst The ratio of the secondary pump s can be changed...

Page 10: ...d Add Add Reducer Reducer Reducer to to to the the the Base Base Base When adding the reducer to the base before proportioning with the Hydra Cat 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 part...

Page 11: ...econdary stroke length increasing its fluid output 1 Use a wrench to rotate the ratio adjustment screw S Rotate the screw clockwise to increase the ratio Rotate the screw counterclockwise to decrease the ratio The indicator pin V will move along the ratio indicator scale U as the ratio adjustment screw is rotated See Fig 1 page 7 2 When the pin is above the desired ratio remove the wrench and perf...

Page 12: ...losion always ground equipment and waste container To avoid static sparking and injury from splashing always flush at lower possible pressure The pumps were tested with lightweight oil at the factory Before operating the pump thoroughly flush the Hydra Cat system to prevent contamination of your fluids Note Flush the mixer hose and gun often enough to prevent fluid from reacting or curing in them ...

Page 13: ... the mixer manifold and trigger your spray gun 2 Set your operating pressure After determining the operating pressure release the spray gun trigger and engage the safety latch 3 Close the mixer manifold inlet valves 4 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 pum...

Page 14: ...not over tighten the packing nut Bearing Bearing Bearing Maintenance Maintenance Maintenance Many of the bearing surfaces on the proportioner are permanently lubricated or are self lubricating However there are four main bearings X on the lever arm that that that must must must be be be lubricated lubricated lubricated on a regular interval The lubrication interval is every six months in single sh...

Page 15: ...very dry install an air line lubricator between the air regulator and the pump air motor for automatic lubrication Refer to the air motor manual for details Figure 3 Key Key Key A Bleeder Type Main Air Valve B Air Motor C Primary Cylinder D Secondary Cylinder E Frame F Air Motor Tie Rods G Fluid Cylinder Tie Rods H Tie Rod Nuts J Connecting Rod Nut Air Motor K Connecting Rod Nut Primary L Connecti...

Page 16: ...ides of the proportioner Turn the main air valve A back on and carefully increase the air pressure 6 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 7 When the operation of the primary side has been verified reconnect the connecting rod L of t...

Page 17: ...l not run or stops while running The displacement cylinder s is damaged or has seized See troubleshooting techniques below to isolate the problem cylinder See Disconnect the Displacement Pump page 19 Air volume is too low Verify that air pressure at the air motor inlet is not dropping during pump changeover Check air compressor and air supply filters regulator lubricator valves and other component...

Page 18: ...oblem cylinder s See Disconnect the Displacement Pump page 19 Running out of one material Check and refill material reservoirs Remember that once air is in the fluid system it may take a while for all of it to escape Spray output is spitting Siphon hoses are leaking in air Tighten and seal all siphon fittings on proportioning pump and feed pumps A squeaking or knocking noise is heard The bearings ...

Page 19: ...me location of displacement pump being removed Each displacement pump must be returned to its original position and orientation NOTICE NOTICE NOTICE To prevent damage to the displacement pump use two people when lifting moving or disconnecting the pump This pump is too heavy for one person Securely brace the pump or have a least two people hold it while another disconnects it 6 Using an adjustable...

Page 20: ...n lifting moving or disconnecting the air motor This air motor weighs 145 lbs and is too heavy for one person to handle A lift ring is provided on the motor for this purpose 4 Note the relative position of the air motor s air connection to the frame E The air motor B must be returned to its original orientation 5 Using an adjustable wrench or hammer and punch unscrew the coupling nut J from the ro...

Page 21: ...fts and remove the retaining washers 6 You should now be able to slide the bearings X 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 X onto the shafts Doing so may require slightly shifting the shaft a...

Page 22: ... 244524 WIRE ground assembly w clamp 1 41 626125 ROD tie 3 50 237074 VALVE relief 2 52 551387 GAUGE pressure fluid 2 Ref Ref Ref Part Part Part Description Description Description Qty Qty Qty 54 155699 FITTING elbow street 1 61 197340 COVER coupler 2 63 106166 NUT mach hex 3 81 244819 COUPLING assembly 145 290 Xtreme 2 85 626262 ADAPTER rod 2 90 626264 NUT coupling 1 91 184130 COLLAR coupling 2 92...

Page 23: ...mensions A Height 66 in 1676 mm B Length 31 5 in 800 mm C Width 33 in 838 mm D Air Inlet 3 4 npt f E Fluid Inlets Two 2 in npt f F Fluid Outlet Two 1 2 in npt f G Relief Valve Outlets Two 1 4 in npt m Net Weight 700 lbs 320 kg 3A3092A 23 ...

Page 24: ...e 25 output or 1000 psi max Maximum Pump Operating Temperature 180 F 82 C Noise level measured at 70 psi 4 8 bar 0 48 MPa and 20 cpm maximum load per ISO 9614 2 86 dBa Wetted Parts Carbon Steel Models Primary and Secondary Pumps 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 Leather...

Page 25: ...Notes Notes Notes Notes 3A3092A 25 ...

Page 26: ...RRANTY WARRANTY WARRANTY AND AND AND DISCLAIMS DISCLAIMS DISCLAIMS ALL ALL ALL IMPLIED IMPLIED IMPLIED WARRANTIES WARRANTIES WARRANTIES OF OF OF MERCHANTABILITY MERCHANTABILITY MERCHANTABILITY AND AND AND FITNESS FITNESS FITNESS FOR FOR FOR A A A PARTICULAR PARTICULAR PARTICULAR PURPOSE PURPOSE PURPOSE IN IN IN CONNECTION CONNECTION CONNECTION WITH WITH WITH ACCESSORIES ACCESSORIES ACCESSORIES EQU...