Graco 3A2012J User's Manual

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Graco 3A2012J User's Manual | Manualzz
Instructions - Parts
FRP Proportioner
3A2012J
EN
Low emission internal/external mix gel coat and chop proportioners. For use with resin
and catalyst in hazardous and non-hazardous locations.
For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual and
all component manuals. Save all instructions.
See page 4 for model and agency approvals information. See page 83 for maximum working pressure and other
specifications. For patent information, see www.graco.com/patents.
WARNING
FIRE AND EXPLOSION HAZARD
Oil left in the system at the factory can react with catalyst and create a fire or explosion.
• Flush before first use.
• Do not add catalyst to the catalyst reservoir until the system has been flushed.
ti18526c
ti18524d
Cart and Boom System
Wall Mount System
ti18496b
Cart System
II 2 Gc T5
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Important Methyl Ethyl Ketone Peroxide (MEKP)
Safety Information . . . . . . . . . . . . . . . . . . . . . . 8
Important Two-Component Material Information . 9
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 9
Keep Resin and Catalyst Components Separate 9
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Component Identification . . . . . . . . . . . . . . . . . . 11
Air Control Panel . . . . . . . . . . . . . . . . . . . . . . . . 12
Air Motor and Resin Displacement Pump . . . . . 13
Catalyst Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Solvent Flush Systems . . . . . . . . . . . . . . . . . . . 15
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Before Installation . . . . . . . . . . . . . . . . . . . . . . . 16
Location Requirements . . . . . . . . . . . . . . . . . . . 16
System Mounting (Wall Mount Systems Only) . 16
System Assembly . . . . . . . . . . . . . . . . . . . . . . . 18
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connect Fluid and Air Lines . . . . . . . . . . . . . . . 21
Flush Before First Use . . . . . . . . . . . . . . . . . . . 23
Fill Supply Tanks . . . . . . . . . . . . . . . . . . . . . . . . 23
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . 24
Pressure Relief Procedure and Shutdown . . . . 24
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DataTrak Operation . . . . . . . . . . . . . . . . . . . . . 33
Replace DataTrak Battery or Fuse . . . . . . . . . . 38
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Catalyst Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Resin Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
General Information . . . . . . . . . . . . . . . . . . . . . . 42
Disconnect the Displacement Pump . . . . . . . . . 42
Reconnect the Displacement Pump . . . . . . . . . 43
Disconnect the Air Motor . . . . . . . . . . . . . . . . . . 44
Reconnect the Air Motor . . . . . . . . . . . . . . . . . . 44
Replace Pumpline . . . . . . . . . . . . . . . . . . . . . . . 46
Repair Catalyst Pump . . . . . . . . . . . . . . . . . . . . 47
System Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Carts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Wall or Pole Mount Kit, 16N918 . . . . . . . . . . . . 57
Boom, 16N761 . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Air Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Slave Pump Linkage, 16P125 . . . . . . . . . . . . . . 60
Resin Pumplines . . . . . . . . . . . . . . . . . . . . . . . . 61
Air Motor and Pump for
Resin Pumpline . . . . . . . . . . . . . . . . . . . . . . 62
Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Resin Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Resin Supply Hose . . . . . . . . . . . . . . . . . . . . . . 64
Catalyst Slave Pumps . . . . . . . . . . . . . . . . . . . 66
Catalyst Reservoir . . . . . . . . . . . . . . . . . . . . . . . 68
Hose Bundles . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Hose Bundles . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Accessory Parts . . . . . . . . . . . . . . . . . . . . . . . . . 72
Heater Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Solvent Pressure Pot Kits . . . . . . . . . . . . . . . . . 74
Solvent Diaphragm Pumps . . . . . . . . . . . . . . . . 76
DataTrak Upgrade Kit . . . . . . . . . . . . . . . . . . . . 77
Carts for 55 Gallon Barrel, 16M896 . . . . . . . . . 78
Roving Box Bracket . . . . . . . . . . . . . . . . . . . . . . 79
Extension Hoses . . . . . . . . . . . . . . . . . . . . . . . . 80
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Cart and Boom . . . . . . . . . . . . . . . . . . . . . . . . . 81
Cart Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Wall/Pole Mount . . . . . . . . . . . . . . . . . . . . . . . . 82
Pumpline Wall Mounting Bracket Dimensions . . 83
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 86
3A2012J
Related Manuals
Related Manuals
Manuals are available at www.graco.com. Component
manuals in English:
Manual
Description
3A0232
3A2313
RS™ Gun Instructions-Parts
U-Cup Displacement Pump
3A2315
332451
308981
309524
NXT® Air Motor for FRP
FRP Stainless Steel Fitting Kit
Air Operated Diaphragm Pumps
Viscon HP Heater Instructions
307363
Viscon® Heater Instructions
313541
DataTrak™ Conversion Kit Instructions
ASME and CE-Approved Pressure Pot
Instructions (Solvent Flush Pressure Pot)
Fluid Outlet Filter
Chop Cart Legs Kit
308370
307273
407019
Manual
Description
407020
407021
407022
407023
407024
55 Gallon Drum Kit
Roving Box Bracket Kit
Deluxe Inlet Seat Removal Tool
5 Gallon Catalyst Reservoir Kit
Boom Kit
407025
407026
407027
407028
407031
DataTrak™ Upgrade Kit
Wall or Pole Mount Kit
Linkage Replacement Kit
Resin Pump Connecting Kit
Diaphragm Pump Solvent Flush Kit
Non-CE Approved Solvent Pressure Pot
Kits
ASME and CE-Approved Pressure Pot
Kits
Heater Kits
407032
407033
407042
Agency Approvals
FRP proportioner systems are approved for use in
hazardous locations when the base model, all accessories, and all kits meet all wiring meet local, state,
and national codes.
Base FRP System with no accessories*
II 2 Gc T5
Accessories
*
See accessory manuals listed in Related Manuals section for approvals.
Solvent pots do not affect Atex rating.
3A2012J
3
Models
Models
Ratio
Internal or
External
Mix
Gel or
Chop
Gel
Internal Mix
Chop
13:1
Gel
External
Mix
Chop
Internal Mix
Gel
17:1
External
Mix
4
Gel
No Cart
Hose
Length
Part No.
ft (m)
Cart
Cart, Mast, and Boom
Hose
Length
Part No.
ft (m)
Part No.
Hose
Length
ft (m)
16R065
25 (7.6)
16R002
25 (7.6)
16R053
25 (7.6)
16R068
35 (10.7)
16R044
35 (10.7)
16R056
35 (10.7)
16R071
50 (15.2)
16R047
50 (15.2)
16R059
50 (15.2)
16R074
---
16R050
---
16R062
---
16R135
25 (7.6)
16R123
25 (7.6)
16R004
25 (7.6)
16R138
35 (10.7)
16R114
35 (10.7)
16R126
35 (10.7)
16R141
50 (15.2)
16R117
50 (15.2)
16R129
50 (15.2)
16R144
---
16R120
---
16R132
---
16R030
25 (7.6)
16R001
25 (7.6)
16R018
25 (7.6)
16R033
35 (10.7)
16R009
35 (10.7)
16R021
35 (10.7)
16R036
50 (15.2)
16R012
50 (15.2)
16R024
50 (15.2)
16R039
---
16R015
---
16R027
---
16R100
25 (7.6)
16R088
25 (7.6)
16R003
25 (7.6)
16R103
35 (10.7)
16R079
35 (10.7)
16R091
35 (10.7)
16R106
50 (15.2)
16R082
50 (15.2)
16R094
50 (15.2)
16R109
---
16R085
---
16R097
---
16R205
25 (7.6)
16R006
25 (7.6)
16R193
25 (7.6)
16R208
35 (10.7)
16R184
35 (10.7)
16R196
35 (10.7)
16R211
50 (15.2)
16R187
50 (15.2)
16R199
50 (15.2)
16R214
---
16R190
---
16R202
---
16R170
25 (7.6)
16R005
25 (7.6)
16R158
25 (7.6)
16R173
35 (10.7)
16R149
35 (10.7)
16R161
35 (10.7)
16R176
50 (15.2)
16R152
50 (15.2)
16R164
50 (15.2)
16R179
---
16R155
---
16R167
---
3A2012J
Accessories
Accessories
To avoid fire and explosion and electric shock, FRP
proportioners are not approved for use in hazardous
locations unless all accessories, all kits, and all wiring
meet local, state, and national codes. See Agency
Approvals on page 3.
The following items can be purchased separately from
the system to gain additional functions. Many of the
items require user installation; refer to the System
Assembly section beginning on page 18 for the
required procedures.
Extension Hoses
Solvent Flush Diaphragm Pumps
Part
Description
16M560
2 Gallon Solvent Flush Diaphragm Pump
16M561
5 Gallon Solvent Flush Diaphragm Pump
Part
Description
16M712
25 ft Extension Hose Bundle for Chop Systems
16M718
25 ft Extension Hose Bundle for Internal Gel
Systems
16M719
25 ft Extension Hose Bundle for External
Gel Systems
55 Gallon Barrel Carts
Solvent Flush Pressure Pots
Part
Description
Part
Description
16M896
55 Gallon Barrel Cart
16M874
2 Gallon, ASME and CE-approved, Solvent
Flush Pressure Pot
Part
Description
16M875
5 Gallon, ASME and CE-approved, Solvent
Flush Pressure Pot
16M961
Roving Box Bracket Kit
16M893
2 Gallon, ASME Solvent Flush Pressure Pot
Part
Description
16M894
5 Gallon, ASME Solvent Flush Pressure Pot
16M881
DataTrak Upgrade Kit
Heaters
Part
Roving Box Bracket
DataTrak Upgrade
5 Gallon Catalyst Reservoir
Description
120V Viscon Heater, for hazardous loca16N014★
tions
Part
Description
24M501
5 Gallon Catalyst Reservoir Kit
Wall Mounting
16N015★
240V Viscon Heater, for hazardous locations
Part
Description
120V Viscon Heater, for hazardous locations and explosive atmospheres
16N918
FRP Pole or Wall Mount Kit
16N016
Pump Connecting Kits
16N017
240V Viscon Heater, for hazardous locations and explosive atmospheres
16N018
120V Viscon Heater, for non-hazardous
locations
16N019
240V Viscon Heater, for non-hazardous
locations
★
Heaters can be disassembled to remove
cured material.
3A2012J
Part
Description
16N242
17:1 Pump Connecting Kit
16N243
13:1 Pump Connecting Kit
5
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are
present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may
look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Engage trigger lock when not dispensing.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
6
3A2012J
Warnings
WARNING
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area
of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of
toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about
your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and
follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• 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 and animals away from work area.
• Comply with all applicable safety regulations.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:
• Do not touch hot fluid or equipment.
3A2012J
7
Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information
Important Methyl Ethyl Ketone Peroxide (MEKP)
Safety Information
MEKP is among the more hazardous materials found in commercial channels. Proper handling of the “unstable
(reactive)” chemicals presents a serious challenge to the plastics industry. The highly reactive property which makes
MEKP valuable to the plastics industry in producing the curing reaction of polyester resins and gel-coats also produces the hazards which require great care and caution in its storage, transportation, handling, processing and disposal.
Workers must be thoroughly informed of the hazards that may result from improper handling of MEKP, especially in
regard to contamination and heat. They must be thoroughly instructed regarding the proper storage, use and disposal of MEKP and other hazardous materials used in the laminating operation.
MEKP is flammable and potentially explosive, as well as potentially damaging to the eyes and skin.
Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related
to MEKP.
Contaminated MEKP can become explosive. Prevent contamination of MEKP with other materials, including
but not limited to polyester overspray, polymerization accelerators and promoters, and non-stainless metals.
Even small amounts of contaminates can make MEKP explosive. This reaction may start slowly, and gradually
build-up heat, which can accelerate until fire or an explosion result. This process can take from seconds to
days.
Heat applied to MEKP, or heat build-up from contamination reactions can cause it to reach what is called its
Self-Accelerating Decomposition Temperature (SADT), which can cause fire or explosion. Spills should be
promptly removed, so no residues remain. Spillage can heat up to the point of self-ignition. Dispose in accordance with manufacture’s recommendation.
Store MEKP in a cool, dry and well-ventilated area in the original containers away from direct sunlight and
away from other chemicals. It is strongly recommended that the storage temperature remain below 86° F
(30° C). Heat will increase the potential for explosive decomposition. Refer to NFPA 432. Keep MEKP away
from heat, sparks and open flames.
Current catalysts are premixed and do not require any diluents. Graco strongly recommends that diluents not
be used. Diluents add to the possibility of contaminates entering the catalyst system. Never dilute MEKP with
acetone or any solvent since this can produce an extremely shock-sensitive compound which can explode.
Use only original equipment or equivalent parts from Graco in the catalyst system (i.e.: hoses, fittings, etc.)
because a hazardous chemical reaction may result between substituted parts and MEKP.
To prevent contact with MEKP, appropriate personal protective equipment, including chemically impermeable
gloves, boots, aprons and goggles are required for everyone in the work area.
8
3A2012J
Important Two-Component Material Information
Polyester Resins and Gel-Coats
Spraying and Lamination Operations
Spraying materials containing polyester resin and
gel-coats creates potentially harmful mist, vapors and
atomized particulates. Prevent inhalation by providing
sufficient ventilation and the use of respirators in the
work area.
Remove all accumulations of overspray, FRP sandings, etc. from the building as they occur. If this waste
is allowed to build up, spillage of catalyst is more likely
to start a fire.
If cleaning solvents are required, read material manufacture’s warnings and material MSDS to know specific hazards and precautions. (Graco recommends
that clean-up solvents be nonflammable.)
Read the material manufacturer’s warnings and material MSDSs to know specific hazards and precautions
related to polyester resins and gel-coats.
To prevent contact with polyester resins and gel-coats,
appropriate personal protective equipment, including
chemically impermeable gloves, boots, aprons and
goggles are required for everyone in the work area.
Graco recommends that you consult OSHA Sections
1910.94, 1910.106, 1910.107 and NFPA No. 33, and
NFPA No. 91 for further guidance.
Important Two-Component Material Information
Material Self-ignition
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
Changing Materials
•
When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
•
Always clean the fluid inlet strainers after flushing.
•
Check with your material manufacturer for chemical
compatibility.
Keep Resin and Catalyst
Components Separate
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or
damage equipment. To prevent cross-contamination
of the equipment’s wetted parts, never interchange
catalyst (usually MEKP) and resin (usually polyester
resin or gel-coat) parts.
3A2012J
9
Overview
Overview
The FRP proportioner dispenses pigmented, tooling,
low-VOC, and specialty gel coats, as well as polyester
resin and vinyl ester chemicals. The FRP proportioner
supplies the individual catalyst and resin materials, and
fiberglass roving to the gun. On internal mix systems, it
also supplies solvent to the gun for clearing mixed material from the gun.
Typical Applications
•
•
•
•
•
•
Marine and watercraft
Pool and spa
Bath ware
Transportation
Corrosion prevention
Cultured marble
FRP proportioner systems are approved for use in
hazardous locations when the base model, all accessories, and all kits meet all wiring meet local, state,
and national codes.
10
3A2012J
Component Identification
Component Identification
F
D
H
N
L
B
A
C
E
WLF
Cart system shown with solvent
flush diaphragm pump and external mix gel gun
Key:
A Cart
B Air Motor
C Resin Displacement Pump
D Catalyst Pump
E Solvent Flush (Diaphragm Pump Option Shown,
Pressure Pot Options also available)*
F Catalyst Reservoir
G Boom (not shown)
M
H
J
K
L
Air Control Panel
Heater (not shown)
Grounding Wire (not shown)
Hook support for resin hose coil
(25 ft and 35 ft hose bundles only)
M Spray gun
N Air/Water Separator (customer supplied)
* Internal mix systems only.
3A2012J
11
Component Identification
Air Control Panel
Air pressure gauge 2 (AG): indicates regulator 2 air
pressure.
Air inlet (AA): from air line.
Air regulator 3 (AH): controls Air Assist Containment™
(AAC™) air to spray gun.
Air regulator 1 (AB): controls air to resin pump.
Air outlet 1 (AC): air line to resin pump.
Air pressure gauge 3 (AK): indicates AAC air pressure.
Air pressure gauge 1 (AD): indicates air pressure to
resin pump.
Air outlet 3 (AM): AAC air line to spray gun.
Air regulator 2 (AE): for external mix guns only: controls catalyst atomization air. For internal mix guns only:
controls solvent flush pressure.
Air outlet 4 (AN): Chop air supply to spray gun. This
outlet is plugged at the factory. Plug must be removed to
install chop air.
Air outlet 2 (AF): for external mix guns only: catalyst air
line to spray gun. For internal mix guns only: to solvent
pump.
Air Shutoff valve (AP): shuts off air to entire system.
FRONT
REAR
AC
AH
AM
AK
AD
AE
AF
ti21338a
AP
ti21339a
AN
AG
AB
AA
FIG. 1: Air Control Panel Components
Air Outlet Fitting
Details
Internal Chop
External Chop
Internal Gel
External Gel
Air Outlet 2 (AF)
3/8 tube
1/4 tube
3/8 tube
1/4 tube
Air Outlet 3 (AM)
1/4 tube
1/8 npt
3/8 tube
1/8 npt
Air Outlet 4 (AN)★
1/2 tube
1/2 tube
Plugged
Plugged
★ Includes a 1/2 to 3/8 reducer to adapt to older chop hose bundles
12
3A2012J
Component Identification
Air Motor and Resin Displacement Pump
The air motor powers the resin displacement pump
which supplies resin to the spray gun.
Air inlet (M): connect air hose to the air inlet.
Fluid filter (N): removes particles from the fluid.
M
Pressure relief/recirculation valve (P): relieves pressure in the hose and gun.
Pressure relief/recirculation fluid outlet (P1): place
container below fluid outlet or connect fluid hose and
route back to the resin container, or install container
below the outlet
R
Pressurized fluid outlet on filter (R): connect fluid
hose to the 1/4 npt(f) fluid outlet reducer fitting supplied
with Graco hoses.
Fluid inlet (S): connect fluid suction hose to the
3/4 npt(m) fluid inlet.
DataTrak (T) (optional): electronic monitoring for material tracking, system diagnostics, and pump runaway
control. The DataTrak is located on the air control panel.
See the NXT Air Motor manual for details of the DataTrak controls and indicators.
3A2012J
ti18499c
P
P1
S
N
FIG. 2
13
Component Identification
Catalyst Pump
The catalyst pump supplies catalyst to the spray gun.
Pump arm (U): controls catalyst flow.
Ratio adjustment knob (V1): use to lock/unlock pump
position and adjust the resin to catalyst ratio. It is easiest
to adjust the ratio when the pump is at the bottom of the
stroke.
V1
U
W
Pivot point (V2): when pump is moved to adjust ratio,
this point stays stationary.
Z2
High pressure relief valve (W): directs catalyst to gun
or back to tank to relieve pressure. It also automatically
relieves pressure if it exceeds normal working pressure.
Z
Z3
Fluid pressure gauge (X): indicates catalyst fluid pressure.
Y
Fluid inlet (Y): fluid inlet from the catalyst reservoir.
Y2
Fluid Inlet Ball Valve (Y2): controls flow of catalyst to
the catalyst pump.
U
Weep line (Z): In the event of a throat seal failure, the
fluid will flow into the weep line and back to the catalyst
reservoir.
X
V2
ti21340a
Z1
Z
Z2
Fluid outlet (Z1): fluid out to the gun.
Z3
Fluid recirculation/high pressure relief (Z2): fluid outlet to the catalyst reservoir.
Low pressure relief valve (Z3): External mix systems
only. Directs catalyst to gun or back to tank to relieve
pressure.
ti21342a
FIG. 3: Catalyst Pump Components
14
3A2012J
Component Identification
Solvent Flush Systems
Solvent Flush Diaphragm Pump
Solvent Flush ASME and CE-Approved Pressure Pot
The solvent flush diaphragm pump provides solvent to
the gun to clear out mixed fluid and prevent it from curing in the gun. See the diaphragm pump manual listed
on page 3 for detailed component identification.
The pressure pot works by using the incoming air pressure to expel the solvent in the pot out of the fluid outlet.
See the ASME and CE-approved Pressure Pot manual
listed on page 3 for detailed component identification.
3/4 npt(f) Fluid
Outlet
1/4 npt(f)
Air Inlet
Air Inlet
Fill Cap
Fluid Outlet
3/4 npt(f)
Fluid Outlet
3/4 npt(f) Fluid Outlet
ti9078a1
FIG. 4: Solvent Pump Components
ti18531a
Solvent Flush ASME Pressure Pot
The pressure pot works by using the incoming air pressure to expel the solvent in the pot out of the fluid outlet.
Verify supply tube is installed on fluid outlet port.
Air Inlet
Fill Cap
Fluid Outlet
ti18530a
3A2012J
15
Setup
Setup
To avoid fire and explosion and electric shock, FRP
proportioners are not approved for use in hazardous
locations unless all accessories, all kits, and all wiring
meet local, state, and national codes. See Agency
Approvals on page 3.
FRP proportioners are not approved for use in hazardous locations unless all accessories, all kits, and all wiring meet local, state, and national codes. See Agency
Approvals on page 3.
This section provides instructions for basic system setup
of the FRP proportioner. See the separate component
manuals for detailed information.
Before Installation
•
Have all system and component documentation
available during installation.
•
See component manuals for specific data on component requirements. Data presented here applies to
the FRP assemblies only.
•
Be sure all accessories are adequately sized and
pressure-rated to meet system requirements. Accessories are available from Graco.
Component identification illustrations are only a guide
for selecting and installing system components and
accessories. Contact your Graco distributor for assistance in designing a system to suit your particular
needs.
•
If using a cart and boom system, ensure there is
enough space overhead and surrounding the proportioner for the boom and mast to fully extend.
•
Place on a flat and level surface.
System Mounting (Wall Mount
Systems Only)
To reduce the risk of skin injection injury, make sure
the system is depressurized before mounting any
pump assembly. See the Pressure Relief Procedure
and Shutdown on page 24.
For ease of operation and service, make sure the pump
air inlet, fluid inlet, and fluid outlet ports are easily
accessible. Mount the catalyst reservoir above the catalyst pump to enable gravity feed. Be sure the bracket is
level.
ti18527d
Location Requirements
Refer to Dimensions, page 81, for mounting and clearance dimensions.
Cart Mount Systems
•
Position the FRP proportioner so the air controls
and catalyst ratio adjustment arm are easily accessible.
NOTICE
To prevent damage to the system caused by the system falling off the wall, be sure the wall can support
the weight of the pump, bracket, hoses and accessories, and stress caused during pump operation.
1. For systems using pole mount:
a. Insert pole clamp bolts through catalyst reservoir mounting plate then each of the two upper
pole clamps, then install and tighten nuts to
secure mounting plate and clamps in place.
16
3A2012J
Setup
NOTE: Catalyst reservoir outlet must be above the catalyst pump inlet fitting for true gravity feeding.
b. Insert pole clamp bolts through pumpline
mounting plate then each of the two lower pole
clamps, then install and tighten nuts to secure
mounting plate and clamps in place.
c.
Use four bolts and washers to secure catalyst
reservoir to catalyst reservoir mounting plate.
d. Use four bolts and washers to secure pumpline
to pumpline mounting bracket.
2. For systems bolting directly to wall (not using a
pole):
a. Use four bolts, washers, and nuts to install catalyst reservoir mounting bracket to wall.
b. Use four bolts, washers, and nuts to install catalyst reservoir onto the catalyst reservoir mounting bracket.
c.
Use four bolts, washers, and nuts to secure
pumpline mounting bracket to wall.
d. Use four bolts, washers, and nuts to secure
pumpline to pumpline mounting bracket.
3A2012J
17
Setup
System Assembly
When the system is shipped from the factory some
items may be shipped loose. Perform the following
instructions to properly install each of the component
items.
1. For cart and boom systems only, install legs:
a. With the system still on the pallet, use the supplied hardware to install the legs onto the base
as shown below. The two longer legs should be
installed on the air control panel side of the
machine. The two non-locking casters should
be installed on the two longer legs.
2. Connect heater (if ordered):
•
•
•
•
Improperly installed or connected equipment may
create a hazardous condition that can cause fire,
explosion, or electric shock.
Refer to heater manual listed on page 3 for
detailed instructions and warnings.
You must have a qualified electrician connect
heater wiring. Ensure wiring and installation comply with local electrical codes for hazardous areas.
Wiring, wiring connections, switches, and electrical
distribution panel must all meet flame-proof (explosion-proof) requirements.
a. Use supplied hardware to install heater onto
pole as shown below. Position the heater to
ease hose routing between pump and heater.
See Heater Kits manual for bolt hole patterns.
ti18523c
b. Use a forklift to raise the system off of the pallet,
remove the pallet, then place item directly on
the floor.
Viscon Heater Shown
ti18529b
b. Connect heater electrical connections. See
heater manual listed on page 3 for detailed
instructions.
18
3A2012J
Setup
3. Install solvent flush diaphragm pump or pressure
pot (if ordered).
a. Use the supplied hardware to install the diaphragm pump or pressure pot onto the base of
the cart in the mounting holes provided.
6. Use the supplied hardware to install the roving box
bracket onto the pole. Install the top pole clamp
above the lower arm of the boom as shown below (if
ordered). If there is a second roving box, use long
hex screws as shown below to secure mounting
plate of second roving box to the mounting plate of
the first roving box.
ti18525b
Solvent Flush Diaphragm Pump shown
ti18455c
b. Use supplied hardware to install solvent supply
tank onto the base of the cart.
4. Install DataTrak Upgrade Kit (if ordered). Follow the
detailed instructions in DataTrak manual listed on
page 3.
5. Assemble the boom as shown below then slide the
boom onto the system pole (if ordered).
Spring
Chain
Roving Guides
Deflector Plates
ti18532b
3A2012J
19
Setup
Grounding
The equipment must be grounded to reduce the risk of
static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current
General Grounding Guidelines
Pump: use ground wire and clamp (supplied). Connect
ground clamp to a true earth ground.
FRP Proportioner Grounding
NOTE: All proportioners come with one grounding
clamp to ground the proportioner to a true earth ground.
All accessories for internal mix systems come with a
second grounding clamp to ground the solvent flush
system to the cart.
1. Verify that the ground screw is attached and tightened securely to the air motor. Connect the other
end of the ground wire to a true earth ground.
Ground
screw
Air and fluid hoses: use only electrically conductive
hoses.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Grounding
wire
ti18454a
FIG. 5: Ground Wire
Fluid supply container: follow local code.
Object being sprayed: follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts
grounding continuity.
2. For internal mix systems only, ground the solvent
flush system.
a. For solvent flush diaphragm pumps only, connect one end of the second grounding clamp to
the solvent pump grounding strip. See the diaphragm pump manual listed on page 3 for
grounding details.
b. Connect the other end of the grounding clamp
to the cart.
3. Use an ohmmeter to verify all components are
grounded to the earth ground.
4. If wall power is used to power the heater, ground
electrical connection according to local codes.
5. For cart proportioners: Connect the other end of the
second supplied grounding clamp to the cart.
For wall proportioners: Connect the other end of the
second supplied grounding clamp to a true earth
ground.
20
3A2012J
Setup
Connect Fluid and Air Lines
Air Connections
1. Verify air line from air outlet 1 (AC) on air control
panel is connected to air inlet (M) on air motor. See
FIG. 2 on page 13 and FIG. 7.
Oil left in the system at the factory can react with catalyst and create a fire or explosion.
• Flush before first use.
• Do not add catalyst to the catalyst reservoir until
the system has been flushed.
2. Connect AAC air line from gun hose bundle to air
outlet 3 (AM) on air control panel. See gun manual
for AAC air line identification.
NOTE: When connecting gun hose bundle, the whip
end connections in the bundle should be connected to
the gun and the non-whip end connections should be
connected to the proportioner. The whip end of the bundle is the end with more flexible lines. See gun manual
for hose bundle connection details and individual hose
identification.
Resin (Whip
Hose)
Solvent/ AAC Air
Catalyst
Air (Chop/
Internal Gel
AAC)
External Atomizing/
Internal Chop AAC Air
3. External mix proportioners only: Connect the supplied air tubing attached to air outlet 2 (AF) to atomized air line on gun.
Internal mix proportioners only: Connect the supplied air tubing attached to air outlet 2 (AF) to solvent pump air inlet. See FIG. 4 on page 15.
4. Chop systems only: Remove plug then connect the
chop air line (0.375 in. tube) in the gun hose bundle
to the chop air fitting (AN) on the air control panel.
5. Verify air shutoff valve (AP) is closed (handle is vertical) then connect the air supply line to the air
inlet (AA) on the air control panel.
FIG. 6: Hose End Diagram
AH
FRONT
REAR
AC
AM
AK
AD
AE
AF
ti21338a
AP
ti21339a
AN
AA
AG
AB
FIG. 7: Air Control Panel Components
Air Outlet Fitting
Details
Internal Chop
External Chop
Internal Gel
External Gel
Air Outlet 2 (AF)
3/8 tube
1/4 tube
3/8 tube
1/4 tube
Air Outlet 3 (AM)
1/4 tube
1/8 npt
3/8 tube
1/8 npt
Air Outlet 4 (AN)★
1/2 tube
1/2 tube
Plugged
Plugged
★ Includes a 1/2 to 3/8 reducer to adapt to older chop hose bundles.
3A2012J
21
Setup
Catalyst Pump Fluid Connections
Resin Pump and Optional Heater Connections
NOTE: See FIG. 3 on page 14.
11. Verify the pressure relief/recirculation valve (W) is
set to pressure relief (knob is horizontal).
M
W
R
ti21343a
ti18499c
FIG. 9: Catalyst Pump Pressure Relief Valve
P
P1
12. Connect the catalyst line from the gun hose bundle
to the catalyst outlet (Z1).
S
N
FIG. 8
6. Verify the pressure relief/recirculation valve (P) is
set to pressure relief.
7. Place a waste container below the fluid outlet then
remove the pump fluid inlet cap. Drain the test oil
then discard.
8. Connect resin suction hose to the resin pump
3/4 nptm fluid inlet (S). Place other end of suction
hose in resin container.
9. For non-heated systems only: Connect resin hose
from the gun hose bundle to the resin pump 1/4 nptf
fluid outlet (R). Reducer fitting comes with Graco
hose bundle.
For heated systems only: attach resin hose from the
gun hose bundle to the heater outlet. Verify fluid
hose connecting resin pump outlet to heater inlet is
installed and secure.
10. Connect resin recirculation hose to the pressure
relief/recirculation line (P1) and route to the resin
container.
22
3A2012J
Setup
Solvent Flush Connections (if applicable)
NOTE: See Solvent Flush Systems component identification on page 15 for connection locations.
13. Connect solvent air line from air control panel to diaphragm pump or pressure pot air inlet.
14. Connect solvent suction tube from solvent supply
tank to solvent pump fluid inlet.
15. Connect solvent line from gun hose bundle to solvent fluid outlet.
Gun Connections
16. For 25 ft and 35 ft hose bundles only: Place the coil
of resin hose in the hose bundle on the hook support located on the pole. Secure with the supplied
rubber straps. The hook support should be inserted
through the center of the hose coil.
17. Secure all connections on the whip-end of the hose
bundle to the gun. See the gun manual listed on
page 3 for detailed instructions.
Flush Before First Use
Oil left in the system at the factory can react with catalyst and create a fire or explosion.
• Flush before first use.
• Do not add catalyst to the catalyst reservoir until
the system has been flushed.
Flush the system before first use to prevent contaminating the resin or catalyst. See page 30.
Fill Supply Tanks
Add fluid to the solvent flush supply tank (if applicable),
the catalyst supply reservoir, and the resin supply container.
3A2012J
23
Operation
Operation
Trigger Lock
Always engage the trigger lock when you stop spraying
to prevent the gun from being triggered accidentally by
hand or if dropped or bumped.
Pressure Relief Procedure and
Shutdown
The equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid such as skin injection, splashing fluid
and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning,
checking or servicing the equipment.
Boom Operation
1. Close the main air supply ball valve.
NOTICE
ti18532b
The height of the boom can be adjusted by adjusting
which link in the chain is secured to the boom arm.
Stop the pump at the bottom of its stroke to prevent
fluid from drying on the exposed displacement rod
and damaging the throat u-cup seals.
2. Turn the main air supply pressure regulator fully
counter-clockwise.
FIG. 10
3. Disengage the trigger lock on the gun. See FIG. 11.
4. With a grounded bucket below the gun, press the
gun against the side of the bucket and pull the trigger to relieve pressure in the fluid lines.
FIG. 11
24
3A2012J
Operation
5. Engage trigger lock.
8. After the pressure is fully relieved, turn the pressure
relief/recirculation valve to dispense position.
FIG. 12
FIG. 15
6. Turn catalyst pump pressure relief/recirculation
valve to the pressure relief position.
9. If you suspect the spray tip, hose, or filter is completely clogged or that pressure has not been fully
relieved after following the previous steps, very
slowly loosen the hose end coupling and relieve
pressure gradually; then loosen completely.
FIG. 13
10. See the gun manual listed on page 3 for shutdown
and maintenance procedures.
7. Verify that the resin pressure relief/recirculation fluid
line is routed to a grounded container, then turn the
pressure relief/recirculation valve to the pressure
relief position.
11. Perform the scheduled maintenance items listed on
page 38.
FIG. 14
3A2012J
25
Operation
Startup
NOTE: Do not exceed 20 psi (0.14 MPa, 1.4 bar) on the
material air pressure regulator until a steady material
flow has been established.
5. As desired, perform Prime, Flush, or Spray procedures beginning on page 27. Make sure to flush the
system before first use to flush out oil used to test
the equipment at the factory.
To avoid overpressurization, before turning on the
main air supply ensure all regulators are adjusted fully
counter-clockwise so they are set to zero pressure.
1. Verify wetcup is filled with Graco Throat Seal
Liquid (TSL™).
2. Ensure main air line is connected to the air control
panel air inlet (AA).
3. For internal mix proportioners only, check solvent
line:
a. Verify gun is ready to begin operation. See gun
manual.
b. Turn shutoff valve (AP) on the air control panel
to the open position.
c.
Open the air valve on the solvent pump and
adjust the solvent pressure to 90 psi (0.63 MPa,
6.3 bar).
d. Open the ball valve on the solvent pump.
e. Open solvent knob on the gun to verify that solvent will flow out of the front of the gun through
the dispense tip, then close the valve.
Oil left in the system at the factory can react with catalyst and create a fire or explosion.
• Flush before first use.
• Do not add catalyst to the catalyst reservoir until
the system has been flushed.
4. If this is the first startup of the machine, perform the
Flush procedure on page 30.
26
3A2012J
Operation
Prime
Perform this procedure upon initial system setup, whenever hoses are disconnected, if the supply hose is
removed from the supply container, or if either pump is
run dry. If done properly, this will prime the lines with
fluid and/or remove any air bubbles from the fluid lines.
NOTE: If using an NXT air motor with DataTrak, see
DataTrak Operation, page 33.
Oil left in the system at the factory can react with catalyst and create a fire or explosion.
• Flush before first use.
• Do not add catalyst to the catalyst reservoir until
the system has been flushed.
2. Verify the resin suction tube is in the resin supply
container. Verify catalyst pump inlet tube is properly
connected to the catalyst reservoir and catalyst
pump fluid inlet ball valve is open. Verify both the
resin supply container and catalyst supply reservoir
have adequate fluid levels.
NOTE: For systems with DataTrak: When priming
pumps, it is normal to get cavitation or pump runaway
alarms. Clear alarms
, and press
again as
necessary. These alarms prevent excessive pump
speeds, which will damage pump packings.
1. To enable the user to better see fluid exiting each
fluid port, the front end of the RS gun can be
removed. This step is optional but can be very useful:
a. Follow Pressure Relief Procedure and Shutdown on page 24.
b. Remove the RS gun front end. See RS gun
manual list on page 3 if desired.
Never allow the pump to run dry of the fluid being
pumped. A dry pump quickly accelerates to a high
speed, possibly damaging itself and causing overpressurization and equipment rupture. If your pump accelerates quickly or is running too fast, stop it immediately
and check the fluid supply. If the supply container is
empty and air has been pumped into the lines, refill the
container and prime the pump and the lines with fluid,
or flush and leave it filled with a compatible solvent. Be
sure to eliminate all air from the fluid system.
3. Units with runaway protection only: enable the
prime/flush function by pushing the prime/flush button on the DataTrak. This prevents the DataTrak
from stopping the pump if it detects a high cycle
rate.
4. Verify the pressure relief/recirculation valves on the
catalyst pump is set to the pressure relief/recirculation position.
FIG. 16
3A2012J
27
Operation
5. Verify the pressure relief/recirculation valves on the
resin pump is set to the pressure relief/recirculation
position.
FIG. 17
10. Turn the catalyst pump pressure relief/recirculation
valve to the dispense position.
FIG. 20
11. Disengage the trigger lock on the gun. See FIG. 21.
6. Turn the main air supply pressure regulator fully
counter-clockwise to relieve pressure and set to
zero pressure. See FIG. 18.
7. Turn the main air supply ball valve to the open position. See FIG. 18.
8. Slowly turn the main air supply pressure regulator
clockwise until the pump starts to move and will
change-over by itself. Never turn past 20 psi
(0.14 MPa, 1.4 bar). See FIG. 18.
To reduce the risk of exposure to the dispensed material mist, when performing the following step use a pail
lid with a hole to dispense through. Seal around hole
and gun with a rag to prevent splash back.
To reduce the risk of skin injection, be careful to keep
fingers away from front of gun.
To reduce the risk of fire and explosion, use a
grounded pail.
FIG. 18
12. Purge air from resin and catalyst hoses: with a
grounded bucket below the gun, press the gun
against the side of the bucket and pull the trigger to
dispense. Continue dispensing until air-free fluid is
dispensed from both ports on the front of the gun.
See FIG. 21. The pump air pressure may need to
increase slightly until the material begins to flow.
9. When material begins to flow and all air bubbles
have been expelled, turn the resin pump pressure
relief/recirculation valve to the dispense position.
FIG. 21
FIG. 19
28
3A2012J
Operation
13. Turn the main air supply ball valve to the closed
position.
FIG. 22
14. Turn the catalyst pump pressure relief/recirculation
valve to the pressure relief position. This will relieve
any built up pressure.
FIG. 23
15. Verify that the resin pressure relief/recirculation fluid
line is routed to a grounded container, then turn the
pressure relief/recirculation valve to the pressure
relief position.
FIG. 24
16. Units with runaway protection only: disable the
prime/flush function by pushing the prime/flush button on the DataTrak.
17. Engage gun trigger lock.
18. If the front end of the gun was removed, apply
grease to o-rings and front of gun to prevent material from curing or sticking to it, then install gun front
end.
3A2012J
29
Operation
Flush
Oil left in the system at the factory can react with catalyst and create a fire or explosion.
• Flush before first use.
• Do not add catalyst to the catalyst reservoir until
the system has been flushed.
To reduce the risk of fire and explosion and skin injection injury, only use a solvent compatible with the system wetted parts, the resin, and the catalyst.
Flush the system:
•
•
•
•
Before first use
When changing fluids
Before repairing equipment
Before fluid dries or settles out in a dormant pump
(check the pot life of catalyzed fluids)
Before storing the pump.
•
Flush at the lowest pressure possible. Flush with a fluid
that is compatible with the fluid you are pumping and
with the wetted parts in your system. Check with your
fluid manufacturer or supplier for recommended flushing
fluids and flushing frequency.
NOTE: Always flush catalyst pump separately by hand
(remove pin from upper control arm and hand pump).
1. Remove all fluid inlet, recirculation, and weep lines
from the catalyst reservoir and insert in a container
filled with a compatible solvent.
2. Remove the resin pump fluid supply and recirculation lines from the resin supply container and insert
in a container filled with a compatible solvent.
NOTICE
To prevent accidentally mixing resin and catalyst in
the solvent container, there must be two solvent
containers used, with the resin pump fluid lines
inserted in one and the catalyst pump fluid lines
inserted in the other.
3. With the fluid lines in the two separate solvent containers, perform the Prime procedure at the lowest
pressure possible. While performing this procedure,
leave the fluid supply, recirculation, and supply lines
in the solvent containers.
30
3A2012J
Operation
Spray
4. Turn the resin pump pressure relief/recirculation
valve to the dispense position.
NOTE: If using an NXT air motor with DataTrak, see
DataTrak Operation, page 33, for instructions on using
the DataTrak counter/totalizer.
Prior to production use, spray onto a clean piece of
paper until all system settings are adjusted to optimize
the spray pattern.
Perform this full procedure whenever the gun has been
unused for an extended period of time, such as overnight. After performing this full procedure, spraying can
be performed intermittently as desired by simply pulling
the trigger and utilizing the trigger lock to prevent accidental triggering.
1. If this is the first time starting up the system, if fluid
lines have been disconnected, if the fluid supply line
has been removed from the supply container, or if
either pump has been run dry, perform Prime procedure on page 27.
2. Turn the main air supply ball valve to the closed
position.
3. Turn the main air supply pressure regulator fully
counterclockwise.
FIG. 26
5. Turn the catalyst pump pressure relief/recirculation
valve to the dispense position. See FIG. 27.
6. Bring catalyst pump fluid outlet line to dispensing
pressure (see FIG. 27):
a. Remove pin connecting upper catalyst pump
arm to air motor rod then manually stroke the
pump until the catalyst pressure gauge shows:
External mix systems: 30-40 psi
(0.21-0.28 MPa, 2.1-2.8 bar).
Internal mix systems: 300-400 psi (2.1-2.8 MPa,
21-28 bar).
b. Insert pin to connect upper catalyst pump arm
to air motor.
FIG. 27
FIG. 25
3A2012J
31
Operation
7. Turn the main air supply ball valve to the open position. See FIG. 28.
8. Slowly turn the main air supply pressure regulator
clockwise until the main air supply pressure gauge
reads the desired pressure. See FIG. 28.
NOTE: In the following step, to minimize catalyst overspray, use as little catalyst atomization air pressure as
possible to achieve desired spray pattern. See the spray
gun manual for instructions.
11. If the spray pattern has not already been set up to
perform as desired, see RS gun manual for detailed
instructions for how to optimize the spray pattern,
including adjusting the AAC air pressure at the system or gun, and adjusting the catalyst atomization
air.
no air
too little air
correct amount
of air
FIG. 28
9. Disengage trigger lock on the gun. See FIG. 29.
10. Pull trigger to begin dispensing. See FIG. 29.
FIG. 30: AAC Air Adjustment
12. After all pressure adjustments are made, spray a
final test shot on a clean piece of paper. This shot
should be approximately 5 ft long. Check desired
gel times and uniformity of curing.
FIG. 29
13. For internal mix proportioners only: When finished
spraying engage trigger lock then point the gun into
a waste container and use the solvent knob on the
gun to move solvent through the gun to flush the
gun.
14. For external mix proportioners only: When finished
spraying, squirt the tip of the gun with solvent to
remove any mixed material.
15. If necessary, use a brush to remove cured material
from front of the gun.
16. If finished spraying for an extended period of time:
Follow Pressure Relief Procedure and Shutdown
on page 24.
32
3A2012J
Operation
DataTrak Operation
For DataTrak installation instructions, see NXT Air
motor for FRP manual.
NOTICE
To prevent damage to the soft key buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
Controls and Indicators
NOTE: See FIG. 31. The display (Y) will turn off after 1 minute of inactivity in Run mode or 3 minutes in Setup mode.
Press any key to wake up the display. DataTrak will continue to count cycles when display is off.
Run Mode
BT
GT
CF; See Details at right.
PF
RK
CF
TI8622b
Setup Mode
RT
UT
CC
DT
*CB
CD
TI11883a
ST
RK
PF
CA
TI8623b
FIG. 31. DataTrak Controls and Indicators
Key:
CA Runaway Limit, in cycles per minute (user settable;
00=OFF)
CB * Lower Displacement (user settable)
CC Flow Rate Units (user settable to
/min, gpm [US],
gpm [Imperial], oz/min [US], oz/min [Imperial], l/min, or
cc/min)
CD LED (fault indicator when lit)
CE Diagnostic Reference Card (see Table 1, page 37)
CF Display
3A2012J
PF Prime/Flush Key (Enables Prime/Flush mode. While in
Prime/Flush mode, runaway protection is disabled and
the batch totalizer (BT) will not count.)
RK Reset Key (Resets faults. Press and hold for 3 seconds to
clear the batch totalizer.)
CF Cycle/Flow Rate
BT Batch Totalizer
GT Grand Totalizer
RT Runaway Toggle (enable/disable)
UT E1 Error Option (enable/disable)
DT E2 Error Option (enable/disable)
ST E5 Error Option (enable/disable)
33
Operation
* 13:1 pump setting is 80cc (for 2 in stroke).
17:1 pump setting is 60cc (for 2 in. stroke).
34
3A2012J
Operation
Setup Mode
1. See FIG. 31. Press and hold
Setup menu appears.
for 5 seconds until
2. To enter settings for runaway, lower size, and flow
rate units, and to enable runaway, E1, E2, and E5
error options, press
NOTE: When runaway, E1, E2, and E5 error options are
enabled, a ✓ will appear on the setup screen. See FIG.
31.
3. Move the cursor to the E5 error enable option field,
then press
once more to exit Setup mode.
to change the value, then
to save the value and move the cursor to the
next data field. See page for a description of E1, E2,
and E5 error codes.
Run Mode
Runaway Monitor
J
1. See FIG. 31. If pump runaway occurs, the runaway
solenoid will actuate, stopping the pump. The LED
(CD) will flash and the display (CF) will indicate a
runaway condition (see Table 1). The display will
cycle through six instruction screens.
2. Runaway Screens 1 and 2: To reset the runaway
solenoid, close the master air valve (AP). Wait for
air to completely bleed off the air motor.
ti11902a
AP
FIG. 32. Solenoid Release Button
4. Runaway Screens 5 and 6: Press
to clear the
diagnostic code and reset the runaway solenoid.
3. Runaway Screens 3 and 4: After the air is bled off,
push the solenoid release button (J) down to reset
the air valve. The button will pop back up when the
air valve is repressurized.
5. Open master air valve (AP) to restart pump.
NOTE: To disable runaway monitoring, go to setup
mode and set runaway value (CA) to 0 (zero) or disable
(RT)
3A2012J
(see FIG. 31).
35
Operation
Prime/Flush
Display
1. See FIG. 31. To enter Prime/Flush mode, press any
See FIG. 31. The display (CF) will turn off after 1 minute
of inactivity in Run mode or 3 minutes in Setup mode.
Press any key to wake up the display.
key to wake up the display, then press
. The
Prime/Flush symbol will appear in the display and
the LED will flash
.
2. While in Prime/Flush mode, runaway protection is
disabled and the batch totalizer (BT) will not count.
The grand totalizer (GT) continues to count.
1. To exit Prime/Flush mode, press any key to wake
up the display, then press
. The Prime/Flush
symbol will disappear from the display and the LED
will stop flashing.
Counter/Totalizer
See FIG. 31. The last digit of the batch totalizer (BT) represents tenths of gallons or liters. To reset the totalizer,
press any key to wake up the display, then press and
hold
•
•
•
NOTE: DataTrak will continue to count cycles when display is off.
NOTE: The display (CF) may turn off if a high-level
static discharge is applied to the DataTrak. Press any
key to wake up the display.
Diagnostics
DataTrak can diagnose several problems with the
pump. When the monitor detects a problem, the LED
(CD, See FIG. 31) will flash and a diagnostic code will
appear on the display. See Table 1.
To acknowledge the diagnosis and return to the normal
operating screen, press
once to wake up the display, and once more to clear the diagnostic code screen
for 3 seconds.
If AC is set to gallons or ounces, BT and GT display gallons.
If AC is set to liters or cc, BT and GT display
liters.
If AC is set to cycles, BT and GT display cycles.
Press
to toggle between flow rate units and cycles.
A letter under the BT display indicates that both BT and
GT are displaying gallons (g) or liters (l). No letter
means both BT and GT are displaying cycles.
36
3A2012J
Operation
Table 1: Diagnostic Codes
Symbol
Code
Diagnosis
Cause
Runaway
Pump running faster than set
(DataTrak only) runaway limit.
• Increased air pressure.
• Increased fluid output.
• Exhausted fluid supply.
E-1
Diving Up
Leak during upstroke.
Worn piston valve or packings.
E-2
Diving Down
Leak during downstroke.
Worn intake valve.
E-3
Low Battery
Battery voltage too low to stop
runaway.
Low battery. Replace battery;
see page 38.
E-4
Service
Problem with stopping runaway. • Damaged solenoid.
Component 1
• Damaged valve carriage.
(units with
• Runaway (RT, FIG. 31) prorunaway
tection may be enabled with
protection only)
pump that is not equipped
with a runaway solenoid
valve. Enter setup screen
and disable runaway protection.
Disconnected
Solenoid is disconnected.
• Solenoid unplugged.
Solenoid
• Damaged solenoid wires.
(units with
Solenoid is not engaging piston • Bracket and solenoid not
runaway
cup.
tight against air valve housprotection only)
ing.
Service
Problem with sensing valve
• Sensors unplugged.
Component 2
movement.
• Sensors mounted incorrectly.
• Damaged sensors.
• Damaged valve carriage.
Blown Fuse
Fuse is blown. Replace fuse;
• Faulty solenoid or solenoid
see page 38.
wiring.
• Extreme temperatures
(above 140°F [60°C]).
• Runaway (RT, FIG. 31) protection may be enabled with
pump that is not equipped
with a runaway solenoid
valve. Enter setup screen
and disable runaway protection.
E-4
E-5
E-6
3A2012J
Code Name
37
Operation
Replace DataTrak Battery or Fuse
4. Remove two screws on back of module to access
battery.
The battery and fuse must be replaced in a
non-hazardous location.
5. Disconnect the used battery and replace with an
approved battery. See FIG. 34.
Use only the following approved replacement batteries. Use of an unapproved battery will void Graco’s
warranty and FM and Ex approvals.
• Ultralife lithium # U9VL
• Duracell alkaline # MN1604
• Energizer alkaline # 522
• Varta alkaline # 4922
Replace Fuse
1. Remove the screw, metal strap, and plastic holder.
2. Pull the fuse away from the board.
3. Replace with a new fuse.
Use only a Graco-approved replacement fuse. Order
Part 24C580.
Solenoid Cable
Connection
Replace Battery
1. Unscrew cable from the back of the reed switch
assembly. See FIG. 33.
2. Remove the cable from the two cable clips.
Fuse
Sensor Cable
Connection
ti11992a
FIG. 33. Disconnect DataTrak
3. Remove DataTrak module from bracket. Take module and attached cable to a non-hazardous location.
Battery
ti11994a
FIG. 34. DataTrak Battery and Fuse Location
38
3A2012J
Maintenance
Maintenance
Task
Schedule
Inspect pump wetcup
and fill with TSL and
remove any particles or
residue
Daily
Remove resin pump
outlet filter and flush
debris
Daily
Inspect hoses for wear
or damage and replace
immediately if found
Weekly
Remove catalyst
reservoir filter and
clean with solvent
As needed
Replace catalyst
reservoir filter
As needed
Flush system
As needed
Components
See component manuals listed on page 3 for maintenance schedules and procedures for each component.
3A2012J
39
Troubleshooting
Troubleshooting
Follow Pressure Relief Procedure and Shutdown
on page 24 before checking or servicing the equipment.
Problems
Try the recommended solutions in the order given for
each problem, to avoid unnecessary repairs.
Catalyst Pump
See Catalyst Slave Pumps parts illustration on page 66 for parts identification.
Problem
Pressure loss on up stroke.
Pressure loss on up stroke and down
stroke.
Cause
Solution
Worn transfer housing seal.
Replace transfer housing seal.
Worn transfer housing seat.
Replace transfer housing.
Worn weep seals.
Replace weep cartridge.
Blow off valve spring is wearing out.
Replace blow off valve.
Loose fittings on spray gun and/or hoses. Tighten fittings on spray gun and hoses.
Scratched piston rod.
Replace piston rod.
Pressure not building on up stroke.
Damaged transfer housing seat.
Replace transfer housing.
Pressure not building on down stroke.
Scratched inlet valve.
Replace inlet valve.
Leakage from cartridge housing.
Loose cartridge housing.
Tighten cartridge housing.
Loose bearing.
Tighten bearing.
Relief valve or check valve has a weak
spring.
Replace relief valve or check valve.
Pump will not prime.
Fluid inlet ball valve is closed.
Open fluid inlet ball valve.
Excessive weepage
Missing snap-on seal retainer
Remove cartridge and install
Worn or damaged snap-on seal retainer
Remove and replace
Pressure being relieved through relief
valve or check valve at a low pressure.
Resin Pump
See Resin Pumplines on page 61 for parts identification.
Problem
Does not operate.
Stall on bottom of
stroke.
40
Cause
Valve closed or clogged.
Solution
Clear air line; increase air supply. Check that
valves are open.
Fluid hose or gun obstructed.
Clean hose or gun.*
Dried fluid on displacement rod.
Clean rod; always stop pump at bottom of stroke;
keep wet-cup filled with Throat Seal Liquid (TSL).
Air motor parts dirty, worn, or damaged.
Clean or repair air motor. See air motor manual.
Runaway error on DataTrak tripped (if DataTrak
installed)
See DataTrak Operation-Runaway Monitor,
page 35.
Runaway solenoid actuated. (if DataTrak installed) Enable runaway protection, if disabled, then see
Runaway, page 35, to reset the runaway solenoid.
3A2012J
Troubleshooting
Problem
Output low on both
strokes.
Cause
Solution
Air line restricted or air supply inadequate. Valves
closed or clogged.
Clear air line; increase air supply. Check that
valves are open.
Fluid hose/gun obstructed.
Clear hose or gun*.
Air motor icing.
See air motor manual for instructions.
Exhausted fluid supply.
Refill and prime pump.
Worn piston packings.
Replace.
Open or worn intake valve.
Clear or service intake valve.
Pump output low on
only one stroke.
Held open or worn ball check valves.
Check and repair.
Worn piston packings.
Replace.
No output.
Improperly installed ball check valves.
Check and repair.
Pump operates erratically.
Exhausted fluid supply.
Refill and reprime pump.
Held open or worn ball check valves.
Check and repair.
Worn piston packing.
Replace.
Suction tube too restrictive, causing pump to cavi- Use larger diameter tube
tate
Erratic accelerated
speed.
Fluid supply exhausted, clogged suction.
Refill supply and prime pump. Clean suction tube.
High viscosity fluid.
Reduce viscosity; increase fluid temperature,
reduce flow rate by using smaller tip.
Open or worn piston valve or seal.
Clear piston valve; replace seal.
Open or worn intake valve.
Clear or service intake valve.
Possible icing.
See air motor manual for instructions.
Filler material clumping causing extra friction on
rods and seals.
Flush pump and replace packings.
Cycles or fails to hold
pressure at stall.
Worn check valves or seals.
Service lower. See lower manual for instructions.
Air bubbles in fluid.
Loose suction line.
Tighten. Use compatible liquid thread sealant or
PTFE tape on connections.
Poor finish or irregular
spray pattern.
Incorrect fluid pressure at gun.
See gun manual; read fluid manufacturer’s recommendations.
Fluid is too thin or too thick.
Adjust fluid viscosity; read fluid manufacturer’s recommendations.
Dirty, worn, or damaged spray gun.
Service spray gun. See spray gun manual.
Inlet ball stuck to seat
Tap pump with hammer to dislodge.
Runs sluggishly.
Difficulty priming
Remove inlet ball, flush dried material, re-install
inlet ball.
Suction hose/strainer too restrictive or clogged
*
Clean inlet strainer, shorten hose length and/or
increase hose diameter (especially cold or viscous
material.
To determine if fluid hose or gun is obstructed, follow Pressure Relief Procedure and Shutdown, page 24. Disconnect fluid hose and place a container at pump fluid outlet to catch any fluid. Turn on air power just enough to
start pump. If pump starts, the obstruction is in fluid hose or gun.
** The runaway solenoid can still be actuated if the Runaway Error is not displayed. Also, disabling the runaway
monitor will not retract the solenoid.
3A2012J
41
Repair
Repair
•
•
•
To reduce the risk of fire and explosion, repair procedures must be performed in a non-hazardous
location. Move system to non-hazardous location
before performing any repair procedure.
Follow Pressure Relief Procedure and Shutdown on page 24 before checking or servicing the
equipment.
To prevent contact with fluids, flush the system
prior to disassembling any components that contain catalyst or resin.
General Information
•
Reference numbers and letters in parentheses in
the text refer to the callouts in the figures and the
parts drawing.
•
Always use Genuine Graco Parts and Accessories,
available from your Graco distributor. If you supply
your own accessories, be sure they are adequately
sized, pressure rated, and made of materials compatible with your system.
Disconnect the Displacement
Pump
See manual 3A2313 for displacement pump service and
parts information.
5. Hold the flats of the air
motor piston rod with a
wrench. Use another
wrench to loosen the
coupling nut.
6. Lower the coupling nut
(A) enough to remove
the coupling collars
(B), and then remove
ti12815a
the coupling nut (A).
Use a magnet to aid removing the two collars (B).
B
A
C
ti12812a
ti12813a
7. Pull up on TSL reservoir (C) to remove.
8. Use a hammer and
brass rod to loosen the
jam nut. Unscrew the
jam nut as far as possible.
9. Protect hands with a
rag then unscrew the
displacement pump by
hand and place on
work bench.
ti12816a
1. Flush the pump, see page 30.
2. Stop the pump in the middle of the stroke.
Threads are very sharp. Use a rag to protect hands
when hand turning or carrying the pump.
3. Relieve the pressure, see page 24.
4. Disconnect the air supply and fluid hoses.
42
10. See displacement pump manual 3A2313 for pump
service procedures and parts information.
3A2012J
Repair
Reconnect the Displacement
Pump
8. Align fluid outlet as shown and tighten the jam nut.
9. Align the TSL reservoir (C) and push it down into
place.
1. Disconnect air supply from air motor.
2. Hand-turn the displacement pump into the adapter
plate.
10. Hold the flats of the motor rod with a wrench. Use
another wrench to tighten the coupling nut (A).
Torque to 75-80 ft-lb (102-108 N•m).
3. Install coupler spring guard and TSL reservoir.
11. Reconnect air supply to motor.
4. Hold the air motor piston rod up with one hand. With
your other hand, put the coupling nut (A) on the displacement rod.
5. Put the coupling
collars (B) into
the coupling nut
(A) so large
flanges point
upward.
B
A
6. Gently let the air
motor piston rod
drop onto the displacement rod.
Hand tighten the
coupling nut (A).
ti12817a
7. Screw the displacement pump into the adapter
plate (D) until the cylinder top is flush with the top of
the adapter plate.
Cylinder, not
wet cup, should
be flush with
plate.
D
ti12814a
FIG. 35. Align cylinder and adapter plate.
3A2012J
43
Repair
Disconnect the Air Motor
8. Lift up on the air motor to remove it. The tie
rods (AJ) will remain attached to the air motor.
See manual 3A2315 for air motor service and parts
information. See FIG. 36 on page 45.
9. Use a socket on the flats of the tie rods (AJ) to
remove them from the bottom of the air motor.
10. See air motor manual 3A2315 for repair procedures
and parts information.
Reconnect the Air Motor
1. Relieve the pressure, see page 24.
2. Disconnect main air supply line from the inlet on the
air control panel (AE).
1. Screw the tie rods (AJ) into the bottom of the air
motor. With a wrench on the flats of the tie rods,
torque to 50-55 ft-lb (68-75 N•m).
3. Disconnect grounding wire.
4. Disconnect items from the air motor:
a. Note location of all air hoses connected to air
motor then disconnect the hoses from the air
motor.
b. Remove top pin (AA) connecting upper catalyst
pump arm to air motor, then remove bolts (AB)
connecting lower catalyst pump arm to air motor
then remove catalyst pump and control arms
assembly (AC).
c.
See FIG. 36 on page 45.
Remove two bolts (AD) securing air control
panel to air motor then remove air control
panel (AE).
5. Hold the flats of the air motor piston rod with a
wrench. Use another wrench to loosen the coupling
nut (A). Lower the coupling nut (A) enough to
remove the coupling collars (B), then remove the
coupling nut (A).
2. Align the tie rods (AF) with the holes in the pump
adapter. Carefully lower the air motor into place.
3. Attach the tie rod nuts (AF) to tie rods then torque to
50-60 ft-lb (68-81 N•m).
4. Install and tighten the screws (AG) that secure air
motor to mounting bracket (AH).
5. Install coupler spring guard and TSL reservoir.
6. With coupling
collars (B) in
place, hand
tighten the coupling nut, then
torque to
75-80 ft-lb
(102-108 N•m).
7. Connect the air
and fluid hoses.
B
A
ti12817a
B
A
The equipment must be grounded to reduce the risk of
static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current
C
ti12812a
ti12813a
6. Use a 23 mm socket to remove the tie rod nuts (AF).
8. Attached grounding wire to true earth ground.
7. Use a 13 mm socket to loosen the top two
screws (AG) that secure air motor to mounting
bracket (AH).
44
3A2012J
Repair
AA
AH
AC
AG
AJ
AK
AB
AF
AE
AD
ti18456c
FIG. 36
3A2012J
45
Repair
Replace Pumpline
This procedure is only needed if the entire pumpline will
be replaced. If just installing repair parts in the air motor
and/or displacement pump, see Disconnect the Displacement Pump on page 42, Disconnect the Air
Motor on page 44, displacement pump manual 3A2313,
and air motor manual 3A2315.
1. Flush the pump, see page 30.
2. Relieve the pressure, see page 24.
3. Disconnect main air line from air panel (AE).
4. Disconnect items from the air motor, see FIG. 36 on
page 45:
a. Note location of all air hoses connected to air
motor then disconnect the hoses from the air
motor.
b. Remove top pin (AA) connecting upper catalyst
pump arm to air motor, then remove bolts (AB)
connecting lower catalyst pump arm to air motor
then remove catalyst pump and control arms
assembly (AC).
c.
Remove two bolts (AD) securing air control
panel to air motor then remove air control
panel (AE).
5. Disconnect the air and fluid hoses.
6. Disconnect the ground wire.
7. Use a socket to loosen the two screws (AG) connecting the air motor to the mounting bracket (AH).
8. Use a socket to remove the two screws (AK) securing the displacement pump to the mounting bracket.
9. Lift up on the pumpline to slide pumpline out of
bracket.
10. Reassembly is reverse of assembly.
46
3A2012J
Repair
Repair Catalyst Pump
See FIG. 37 on page 49 for reference numbers.
Remove Catalyst Pump from System
14. Use crescent wrench to loosen then remove the
bearing (902b) and felt wiper (902d) assembly.
15. Remove seal (902f) from inside of cartridge (902a).
16. Remove o-ring (902g).
1. Flush the pump, see page 30.
2. Relieve the pressure, see page 24.
3. Close catalyst supply ball valve and disconnect fluid
lines.
4. Remove top pivot knob securing catalyst pump to
upper control arm.
5. Remove bolt securing catalyst pump to lower control arm then remove catalyst pump.
Disassemble Catalyst Pump
17. Install new seal (902f) into bottom of the
cartridge (902a) with the u-cup opening facing into
the pump.
18. Install seal (902f) with onto weep seal installation
tool 16N967 with u-cup opening facing into the
pump then use tool to install seal into inside of
cartridge (902a).
19. Install felt wiper (902d) and bearing (902b) into
cartridge (902a). Tighten to 20-60 in-lb
(2.3-6.8 N•m).
6. Pull pivot knob (929) out to fully extend the slave
pump rod (910).
20. Install o-ring (902g).
7. Remove quick release pin (908) from slave pump
housing (901).
22. Lubricate the piston rod.
8. Holding the slave pump housing (901) stationary
with one hand, use a crescent wrench on the flats of
the slave pump cylinder (918) to loosen then
remove the cylinder and foot valve (922) assembly.
21. Install snap-on seal (902e).
23. With bullet tool 16D007 installed on the piston rod,
install cartridge assembly (902) onto the rod.
24. Remove the bullet tool.
9. Place the slave pump housing (901) in a vise. Use
the flats provided by the quick-release pin (908)
hole.
25. Use one wrench on the transfer housing (914) and
another on the transfer housing cap (917) to break
them loose from each other then remove the cap
from the housing.
10. Use a crescent wrench on the flats of the
cartridge (902) to loosen then remove the cartridge
and piston rod (910) assembly.
26. Remove seal (915) and guide (916) from transfer
housing.
Repair Throat and Piston Seals
27. Remove spring (911), valve (912), and o-ring (913)
from transfer housing.
11. Use a wrench on the flats of the piston rod (910) to
hold it stationary while using a second wrench on
the flats of the transfer housing (914) to loosen then
remove the housing and cap (917) assembly.
28. Remove o-ring (913) from the valve (912).
29. Install new o-ring (913) on new valve (912).
12. Install bullet tool 16D007 on the piston rod (910)
then pull the rod (910) out of the cartridge (902).
NOTICE
Bullet tool 16D007 must be used or damage to the
seals will result when removing or installing items
onto the rod.
13. Remove snap-on seal retainer (902e) then remove
seal (902f).
3A2012J
47
Repair
30. Hold spring (911) upright, place valve (912) on top
of spring, slide transfer housing (914) upside down
over the spring then flip upright.
31. Install transfer housing (914) onto piston rod (910).
Use flats on rod and transfer housing to torque
transfer housing against the piston rod to 30-50 in-lb
(3.4-5.6 N•m).
32. Slide the cartridge (902) down against the transfer
housing (914).
33. Install u-cup (915) onto transfer housing with u-cup
opening facing up towards the rod.
34. Install guide (916) onto transfer housing.
35. Install transfer housing cap (917) onto transfer
housing. Use flats to torque to 30-50 in-lb
(3.4-5.6 N•m).
Repair Foot Valve
36. Use wrench to loosen lock nut (921) then remove
cylinder (918) from foot valve (922).
37. Remove ball (925) from foot valve.
38. Remove backup o-ring (920) and o-ring (919) from
both ends of the cylinder (918).
39. Remove ball seat (923). Tool 24N253 can be used
to aid ball seat removal.
40. Place new ball seat onto seat installation tool
16N996 with lip opening facing in towards tool.
Assemble Catalyst Pump
46. Verify cartridge (902) is pressed against the transfer
housing (914).
47. Lubricate the o-ring (902g) on the cartridge.
48. Apply thread sealant to the threads of the
cartridge (902a).
49. With the slave pump housing (901) in a vise, carefully thread the cartridge (902) into the housing.
Torque the cartridge to 240 in-lb (27.1 N•m).
50. Lubricate the o-rings (919, 920) on the
cylinder (918).
51. Hand-thread the cylinder (918) into the slave pump
housing (901) all the way until the cylinder bottoms
out. Rotate the cylinder counterclockwise less than
1/2 turn until the flat on the cylinder is parallel with
the quick-release pin hole then insert the
quick-release pin (908).
52. With the quick-release pin in place, rotate the foot
valve counterclockwise less than one full-turn so
that it is facing directly backwards relative to the
pressure gauge.
53. Hold the foot valve in position and tighten the lock
nut (921) against the foot valve to 225-275 in-lb
(25.4-31.1 N•m).
54. Push the piston rod (908) down into the slave pump
housing (901).
41. Place tool into foot valve then tap with a hammer
until ball seat is properly seated then remove tool.
42. Install new backup o-ring (920) and o-ring (919)
onto both ends of the cylinder (918). Make sure to
install the o-rings in the correct position, with the
backup o-rings towards the center of the cylinder.
43. Lubricate the backup o-rings (920) and
o-rings (919).
44. Install ball into foot valve.
45. Thread cross-cut end of cylinder into foot valve by
hand until it bottoms out but do not tighten the jam
nut.
48
3A2012J
Repair
5
929
927
928
11
5
902d
926 12
910
902b 13
2 12 8
902 1
902f
4
902a
901
1
1
946
1
935
6
909
932
947
1
903
1
1
902g
902f
902e 14
5
907
903a
3
6
ti19060a
911
912
913
914
6
909
908
6
8
915 7
916
903c
903b 3
1 Apply pipe sealant to threads.
917 8
919
2 Apply thread locker to mating surfaces or threads.
920
918
3 Apply grease to mating surfaces or threads.
9 10
4 Torque to 240 in-lb (27.1 N•m).
920
5 Torque to 225-275 in-lb (25.4-31.1 N•m).
919
6 Loop large end of lanyard over gauge prior to
assembling gauge. Attach small end of lanyard to
split ring on pin.
925
5
921
945
923
1
7 Note orientation of u-cup.
Internal Mix shown
8 Torque to 30-50 in-lb (3.4-5.6 N•m).
9 Clean cylinder inner diameter with soft cloth or
940
930
922
11
924
924
equivalent, prior to assembly.
1
1
ti21344a1
11
External Mix Only
932
1
946
947 1
1
10
Hand tighten cylinder (918) and bottom out to
housing (901). Back-off cylinder (918) less than 1/2
turn. Assembly pin (908).
11
Press fit bearings.
12
Torque piston rod (910) to top link (926) to
80-100 in-lb (9.0-11.3 N•m).
13
Torque to 20 - 60 in-lb (2.3-6.8 N•m).
14
Snap 902e onto 902a.
939
938
939
FIG. 37: Catalyst Pump Details
3A2012J
947 1
937 1
934 1
49
System Parts
System Parts
Systems
121
152
111
4 107
5 106
4
105
7
110
108
108
1
109
113
103
104 8
113
102
8 104
114,115,116
122
ti19056b
1 Loosen grounding lug locknut and washer, insert
grounding wire into slot in lug and tighten locknut
securely.
4 Apply grease to outer diameter, not to the threads.
5 Torque to 45-55 ft-lb (61-75 N•m).
7 Connect tubing to catalyst pump.
8 Torque to 20-30 ft-lb (27-41 N•m).
50
3A2012J
System Parts
Systems
124◆
16R027
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
6
1
1
1
1
6
1
1
1
1
1
6
1
1
1
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
3
1
1
3
1
1
3
1
1
1
3
1
1
3
1
1
3
1
1
1
1
1
1
2
1
1
3
1
3
1
16R024
1
2
1
1
16R021
1
1
1
1
1
16R018
1
1
1
16R015
1
1
1
1
16R012
118
119◆
121
122
123◆
1
1
6
1
1
1
1
16R009
116
1
1
1
6
1
1
1
1
16R006
SPACER, ball joint
112◆
113
114
115
6
1
1
1
1
1
1
16R005
24M692
109
110
111
1
1
16R004
152
104
105
106
107
108
1
1
16R003
125◆
126◆
151◆ ▲
----W13DFC
W17CFS
111799
16P125
119999
24M092
16N741
16N740
120476
111040
16M564
16M565
16N761
16U750
113093
114109
121141
16D939
114109
121141
--238909
--124071
16M588
16M587
16M586
16M591
16M590
16M589
16M585
16M584
16M583
258970
258840
258971
258853
16M736
16M810
16D136
Description
WALL OR POLE MOUNT KIT
(No Cart)
CART, for use with boom
CART
PUMP, FRP, 13:1
PUMP, FRP, 17:1
SCREW, cap, hex head
HARNESS, slave linkage
BOLT, shoulder
PIN, quick release, 1.5 x 0.25
PUMP, slave, external mix
PUMP, slave, internal mix
BOLT, shoulder, 5/16
NUT, lock, insert, nylock, 5/16
LABEL, ratio, 13:1, FRP
LABEL, ratio, 17:1, FRP
BOOM KIT
PANEL, air control
FITTING, connector, 1/4 nptf
FITTING, elbow, male, swivel
FITTING, elbow, swivel, 3/8t 1/4mnpt
FITTING, nipple, reducing
FITTING, elbow, male, swivel
FITTING, elbow, male, swivel
TUBING, nylon, round
WIRE, grounding
TUBE, nylon, round
PLUG, fitting, push-to-connect
HOSE, bundle, 25 ft external gel
HOSE, bundle, 25 ft internal gel
HOSE, bundle, 25 ft chop
HOSE, bundle, 35 ft external gel
HOSE, bundle, 35 ft internal gel
HOSE, bundle, 35 ft chop
HOSE, bundle, 50 ft external gel
HOSE, bundle, 50 ft internal gel
HOSE, bundle, 50 ft chop
GUN, external mix, chop, with cutter
GUN, external mix, gel
GUN, internal mix, chop, with cutter
GUN, internal, gel
SUPPLY HOSE, 55 gallon
KIT, FRP
LABEL, warnings
103
Part
16N918
16R002
Ref.
102
16R001
See Models table on page 4 for detailed descriptions of each system number to identify which system number you
have. To make reading the table below easier, find your system number in the left-most column then place a
straight-edge (such as the edge of a blank piece of paper) below that row of the table. If necessary, use a second
straight-edge vertically in the table to identify the part number of each item used in the system.
1
1
1
3
1
3
1
3
1
1
1
3
1
1
1
3
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
◆ Item not shown.
▲ Replacement Danger and Warning labels, tags and cards are available at no cost.
3A2012J
51
Ref.
102
103
104
105
106
107
108
109
110
111
112◆
113
114
115
116
118
119◆
121
122
123◆
124◆
125◆
126◆
151◆ ▲
152
Part
16N918
16R030
16R033
16R036
16R039
16R044
16R047
16R050
16R053
16R056
16R059
16R062
16R065
16R068
16R071
16R074
16R079
16R082
16R085
16R088
16R091
16R094
16R097
System Parts
Description
WALL OR POLE MOUNT KIT
(No Cart)
--CART, for use with boom
--CART
W13DFC PUMP, FRP, 13:1
W17CFS PUMP, FRP, 17:1
111799 SCREW, cap, hex head
16P125 HARNESS, slave linkage
119999 BOLT, shoulder
24M092 PIN, quick release, 1.5 x 0.25
16N741 PUMP, slave, external mix
16N740 PUMP, slave, internal mix
120476 BOLT, shoulder, 5/16
111040 NUT, lock, insert, nylock, 5/16
16M564 LABEL, ratio, 13:1, FRP
16M565 LABEL, ratio, 17:1, FRP
16N761 BOOM KIT
16U750 PANEL, air control
113093 FITTING, connector, 1/4 nptf
114109 FITTING, elbow, male, swivel
121141 FITTING, elbow, swivel, 3/8t
1/4mnpt
16D939 FITTING, nipple, reducing
114109 FITTING, elbow, male, swivel
121141 FITTING, elbow, male, swivel
--TUBING, nylon, round
238909 WIRE, grounding
--TUBE, nylon, round
124071 PLUG, fitting, push-to-connect
16M588 HOSE, bundle, 25 ft external gel
16M587 HOSE, bundle, 25 ft internal gel
16M586 HOSE, bundle, 25 ft chop
16M591 HOSE, bundle, 35 ft external gel
16M590 HOSE, bundle, 35 ft internal gel
16M589 HOSE, bundle, 35 ft chop
16M585 HOSE, bundle, 50 ft external gel
16M584 HOSE, bundle, 50 ft internal gel
16M583 HOSE, bundle, 50 ft chop
258970 GUN, external mix, chop, with cutter
258840 GUN, external mix, gel
258971 GUN, internal mix, chop, with cutter
258853 GUN, internal, gel
16M736 SUPPLY HOSE, 55 gallon
16M810 KIT, FRP
16D136 LABEL, warnings
24M692 SPACER, ball joint
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1
1 1 1
1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
6
1
1
1
6
1
1
1
6
1
1
1
6
1
1
1
6
1
1
1
6
1
1
1
6
1
1
1
6
1
1
1
6
1
1
1
6
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1
1 1 1 1
1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2
1 1 1 1
1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
3 3 3
1 1 1 1 1 1 1
3 3 3 3 3 3 3
1 1 1 1 1 1 1
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1 1 1 1 1 1 1 1
3 3 3 3 3 3 3 3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1
1
1 1 1
1 1 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
◆ Item not shown.
▲ Replacement Danger and Warning labels, tags and
cards are available at no cost.
52
3A2012J
Ref.
102
103
104
105
106
107
108
109
110
111
112◆
113
114
115
116
118
119◆
121
122
123◆
124◆
125◆
126◆
151◆ ▲
152
Part
16N918
16R100
16R103
16R106
16R109
16R114
16R117
16R120
16R123
16R126
16R129
16R132
16R135
16R138
16R141
16R144
16R149
16R152
16R155
16R158
16R161
16R164
16R167
System Parts
Description
WALL OR POLE MOUNT KIT
(No Cart)
--CART, for use with boom
--CART
W13DFC PUMP, FRP, 13:1
W17CFS PUMP, FRP, 17:1
111799 SCREW, cap, hex head
16P125 HARNESS, slave linkage
119999 BOLT, shoulder
24M092 PIN, quick release, 1.5 x 0.25
16N741 PUMP, slave, external mix
16N740 PUMP, slave, internal mix
120476 BOLT, shoulder, 5/16
111040 NUT, lock, insert, nylock, 5/16
16M564 LABEL, ratio, 13:1, FRP
16M565 LABEL, ratio, 17:1, FRP
16N761 BOOM KIT
16U750 PANEL, air control
113093 FITTING, connector, 1/4 nptf
114109 FITTING, elbow, male, swivel
121141 FITTING, elbow, swivel, 3/8t
1/4mnpt
16D939 FITTING, nipple, reducing
114109 FITTING, elbow, male, swivel
121141 FITTING, elbow, male, swivel
--TUBING, nylon, round
238909 WIRE, grounding
--TUBE, nylon, round
124071 PLUG, fitting, push-to-connect
16M588 HOSE, bundle, 25 ft external gel
16M587 HOSE, bundle, 25 ft internal gel
16M586 HOSE, bundle, 25 ft chop
16M591 HOSE, bundle, 35 ft external gel
16M590 HOSE, bundle, 35 ft internal gel
16M589 HOSE, bundle, 35 ft chop
16M585 HOSE, bundle, 50 ft external gel
16M584 HOSE, bundle, 50 ft internal gel
16M583 HOSE, bundle, 50 ft chop
258970 GUN, external mix, chop, with cutter
258840 GUN, external mix, gel
258971 GUN, internal mix, chop, with cutter
258853 GUN, internal, gel
16M736 SUPPLY HOSE, 55 gallon
16M810 KIT, FRP
16D136 LABEL, warnings
24M692 SPACER, ball joint
1 1 1 1
1 1 1 1
1 1 1
1 1 1 1
1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1
6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1
1
1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1
1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1
1
6
1
1
1
1
1
6
1
1
1
1
1
6
1
1
1
1
1
3
1
3
1
3
1
3
1
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
1
1
1 1 1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
1
1
1
1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1
1
1 1 1
1 1 1
1
3
1
3
1
3
1
3
1
3
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1 1 1 1 1 1 1 1
3 3 3 3 3 3 3 3
1 1 1 1 1 1 1
1
1
1
1
1
1
1
1
6
1
1
1
1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1
3
1 1 1 1 1
3 3 3 3 3
1
1
6
1
1
1
1
1
1
1
1
1
1 1
1 1 1
1 1 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1
1 1 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
◆ Item not shown.
▲ Replacement Danger and Warning labels, tags and
cards are available at no cost.
3A2012J
53
Ref.
102
103
104
105
106
107
108
109
110
111
112◆
113
114
115
116
118
119◆
121
122
123◆
124◆
125◆
126◆
151◆ ▲
152
Part
16N918
Description
WALL OR POLE MOUNT KIT
(No Cart)
--CART, for use with boom
--CART
W13DFC PUMP, FRP, 13:1
W17CFS PUMP, FRP, 17:1
111799 SCREW, cap, hex head
16P125 HARNESS, slave linkage
119999 BOLT, shoulder
24M092 PIN, quick release, 1.5 x 0.25
16N741 PUMP, slave, external mix
16N740 PUMP, slave, internal mix
120476 BOLT, shoulder, 5/16
111040 NUT, lock, insert, nylock, 5/16
16M564 LABEL, ratio, 13:1, FRP
16M565 LABEL, ratio, 17:1, FRP
16N761 BOOM KIT
16U750 PANEL, air control
113093 FITTING, connector, 1/4 nptf
114109 FITTING, elbow, male, swivel
121141 FITTING, elbow, swivel, 3/8t
1/4mnpt
16D939 FITTING, nipple, reducing
114109 FITTING, elbow, male, swivel
121141 FITTING, elbow, male, swivel
--TUBING, nylon, round
238909 WIRE, grounding
--TUBE, nylon, round
124071 PLUG, fitting, push-to-connect
16M588 HOSE, bundle, 25 ft external gel
16M587 HOSE, bundle, 25 ft internal gel
16M586 HOSE, bundle, 25 ft chop
16M591 HOSE, bundle, 35 ft external gel
16M590 HOSE, bundle, 35 ft internal gel
16M589 HOSE, bundle, 35 ft chop
16M585 HOSE, bundle, 50 ft external gel
16M584 HOSE, bundle, 50 ft internal gel
16M583 HOSE, bundle, 50 ft chop
258970 GUN, external mix, chop, with cutter
258840 GUN, external mix, gel
258971 GUN, internal mix, chop, with cutter
258853 GUN, internal, gel
16M736 SUPPLY HOSE, 55 gallon
16M810 KIT, FRP
16D136 LABEL, warnings
24M692 SPACER, ball joint
16R170
16R173
16R176
16R179
16R184
16R187
16R190
16R193
16R196
16R199
16R202
16R205
16R208
16R211
16R214
System Parts
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1
1
6
1
1
1
1
1
6
1
1
1
1
1
6
1
1
1
1
1
6
1
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1
6
1
1
1
1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1
1
1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1
1
1
1
1
1
1
1
1
1 1 1 1 1
1
1 1 1 1 1
1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2
1 1 1 1
1 1 1 1
3 3 3
1 1 1 1 1 1 1
3 3 3 3 3 3 3
1 1 1 1 1 1 1
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
1
1
1
1
1
1
1
1
1
1 1 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
◆ Item not shown.
▲ Replacement Danger and Warning labels, tags and
cards are available at no cost.
54
3A2012J
System Parts
Carts
201
202
203
204
205
210
211
207 1
208 1
209
Ref
201
202
203
204
205
207◆
208◆
209
210
211◆
221
222
223
224
Part
----16P425
100023
110837
111040
16V707
16V703
----16V733
16M465
113962
100321
122051
Description
CART, chop
CART, pole
RESERVOIR, gravity feed, 2.5 gallon
WASHER, flat
SCREW, flange, hex
NUT, lock, insert, nylock, 5/16
BUSHING, filter, tank
FITTING, 3/8 tube x 1/4 npt; sst
TUBE, polyethylene, 0.375 OD
TUBE, polyethylene, 0.250 OD
FILTER, tip (3-pack)
CASTER, locking (not shown)
WASHER (not shown)
NUT (not shown)
CASTER, non-locking (not shown)
1 Apply sealant to threads.
Quantity
Cart, for Cart, not
use with
for use
boom with boom
1
1
1
1
4
4
4
4
4
4
1
1
1
1
1.5
1.5
5
5
1
1
2
4
4
4
2
◆ Included in Catalyst Outlet Kit 16N854.
3A2012J
55
System Parts
56
3A2012J
System Parts
Wall or Pole Mount Kit, 16N918
NOTE: For systems that do not use a cart. Can be used to mount to a wall or pole.
302
309,310,311
312
301
305,306,307,308
303
ti18528c
304
Pole not included
Ref
301
302
303◆
304◆
305◆
306◆
307◆
308◆
309
310
311
312
Part
16M666
16M466
------------110837
100023
111040
111799
Description
BRACKET, pump, pole mount
BRACKET, catalyst tank
CLAMP, pipe, set
PLATE, cover, clamp
SCREW, cap, hex head
WASHER, hardened, sae
NUT
WASHER, lock, spring
SCREW, flange, hex
WASHER, flat
NUT, hex
SCREW, cap, hex head
Qty
1
1
4
4
8
8
8
8
4
4
4
4
◆ Included in pipe clamp kit 16P291.
3A2012J
57
System Parts
Boom, 16N761
401
411
412
413
410
408
ti19076a
401
407
414
412
409
406 405
404
403
1 Item shown for reference only.
2 2 in. ID schedule 40 pipe not included.
NOTE: Use rubber straps to secure gun hoses to boom.
Ref
401
402◆
403
404
405
406
407
408
409
410
411
412
413
414
Part
--22546-00
16M626
22486-00
100016
100015
100103
16M811
112248
105170
444
555626
16M808
16N950
Description
SUPPORT, boom, mast
STRAP, binding, rubber, reusable
COVER, roving, guides
GUIDE, roving, ceramic
WASHER, lock
NUT, hex mscr
PIN, cotter
CHAIN, spring, boom
NUT, hex
SCREW, cap hex head
SPRING, boom
WASHER, 1/4 plain flat big
PIN, clevis with cotter pin
EXTENSION, boom
Qty
1
10
5
12
12
12
1
1
1
1
1
2
1
1
◆ Not shown.
--- Not for sale.
58
3A2012J
System Parts
Air Panel
510
505
533
504
541
510
517
503
531
537 542
509
501
522
1
520
541
506
511
529
527
504
538
525
509
521
502
540
522
512
522
539
509
514
515
ti19058b
519
1 Plug supplied with regulator (504).
2 Apply sealant to all non-swiveling pipe threads.
Ref
501
502
503
504
505
506
509
Part
--15T536
15T538
116513
116514
15T500
15T866
510
15T498
511
15T937
512
514
515
----121212
517
519
520
16U556
124071
---
3A2012J
Description
Qty
PANEL, air control
1
REGULATOR, air, 3/8 npt
1
NUT, regulator
1
REGULATOR, air
2
NUT, regulator
2
GAUGE, pressure, air, 1/8
3
FITTING, elbow, swivel, 1/8 npt
2
x 5/32 t
FITTING, 90°, swivel, 5/32t x
3
1/8fnpt
FITTING, elbow, male, 1/4
1
npt(m) x 5/32 OD tube
VALVE, ball, 1/2 npt x 1/2 npt
1
FITTING, straight, 1/2 x 3/8 tube
1
FITTING, elbow, swivel, 1/2 t x
2
3/8 npt(m)
LABEL, air control panel, FRP
1
PLUG, fitting, push-to-connect
1
TUBING, air, 3/8 in. OD;
0.18
polyurethane
Ref
521
522
525
527
529
531
533
537
538
539
540
541
542
Part
Description
Qty
--TUBE, polyethylene; 1/2 in. OD 0.68
--TUBE, nylon, round, black
1.37
114381 SCREW, cap, button head
3
124496 VALVE, air check
1
--BRACKET, air control
1
113498 VALVE, safety, 110 psi
1
--INSERT, control panel
1
96/0005- WASHER, lock, ext, #10, ms
2
2/99
16U452 FITTING, elbow, 1/4npt(m) x
1
1/2 tube
16U479 FITTING, cross, 1/2 tube,
1
plastic
16U480 FITTING, 1/2 stem x 1/2npt(m),
1
plastic
16U481 FITTING, tee, 1/4 npt(m), 3/8 t,
2
1/4 npt(f)
105332 NUT, lock
2
59
System Parts
Slave Pump Linkage, 16P125
2001a
2001d
2001e
2001f
2001c
2005
2001b
2006
2007
2008
2002
2003
Ref
2001
2001a
2001b
2001c
2001d
2001e
2001f
2002
2003
2004
2005
2006
2007
2008
Part
--16N776
16N775
119999
116969
7486-05
7486-03
16M362
116596
119999
16N774
24M092
111040
120476
2004
ti19057a
Description
HARNESS, slave linkage
KIT, upper link, slave
KIT, lower link, slave
BOLT, shoulder
NUT, lock
WASHER, flat, standard, #10
WASHER, flat, fender, 1/4
LINK, fixed, pivot
SCREW, cap, hex head
BOLT, shoulder
LINK, yoke, upper, assy
PIN, quick release, 1.5 x 0.25
NUT, lock, insert, nylock, 5/16
BOLT, shoulder, 5/16
Qty
1
1
1
1
1
1
1
1
2
1
1
1
1
1
Ratio Indicator labels (111), 75cc (16M565) and
100cc (16M564), are not included. Purchase separately.
60
3A2012J
System Parts
Resin Pumplines
Quantity
609 5
617 7
614
Ref
Part
601
M07LNL MOTOR, double
ended, 4.5 in.
1
1
601
602*
15M662 ROD, tie
3
3
603*
16U435 ADAPTER, displacement pump
615
613
1 602
616
610
604
605*
6 607
618
1
LW100C PUMP, 100 cc
1
15U606 NUT, lock, M16 x 2
3
3
COLLAR, coupling
(10 pack)
2
2
607*
15T311
NUT, coupler
1
1
608*
24A625
RESERVOIR, TSL,
75cc lower
(includes 618)
24A626
RESERVOIR, TSL,
100cc lower
(includes 618)
2 605
1 Torque to 50-55 ft-lb (68-75 N•m).
plus or minus one thread. Packing nut will extend above
the surface of pump adapter (603). Torque jam nut to
70-75 ft-lb (95-102- N•m).
1
1
610
16M362 LINK, fixed, pivot
1
1
611
116596
SCREW, cap, hex
head
2
2
612
24F620
FILTER, fluid,
5000 psi
1
1
613
24D642 MUFFLER
1
1
614
100361
1
1
615
16M355 FITTING, adapter,
muffler, 1/2 npt x
1 in. - 14
1
1
616*
16M477 SPRING, guard
1
1
617
15V204
FITTING, elbow,
1/2 npt x 1/2 tube
1
1
O-RING, wetcup
1
1
618*† ---
5 Torque to 70-75 ft-lb (95-102 N•m).
*
7 Apply thread sealant.
3A2012J
1
16N774 LINK, yoke, upper
4 Torque to 250 in-lb (28.2 N•m)
6 Torque to 75-80 ft-lb (102-108 N•m).
1
609
2 Torque to 50-60 ft-lb (68-101 N•m).
3 Assemble pump (604) to top of pump adapter (603),
1
606*† 24A619
3
612
1
16U426 ADAPTER, displacement pump
603
3 604
Description
LW075S PUMP, 75 cc
611 4
606
608
W13DFC, W17CFS,
13:1
17:1
PLUG, pipe
Included in Connecting Kit. See page 62 to order the
correct kit for your pump.
† See Resin Pumpline Kits on page 62.
61
System Parts
Resin Pumpline Kits
Kit Description
LW075S
LW100C
Wet-Cup O-Ring (618)
Package of 10
24A631
24A632
Coupling Collars (606)
Package of 10
24A619
24A619
16N242
16N243
Connecting Kit
Includes pump adapter (603), three tie rods
(602), three tie rod nuts (605), TSL
reservoir (608) and TSL bottle, adapter (603),
coupling nut (607), three coupling collars (606),
tie rod spring guard (616).
NOTE: For displacement pump repair kits, see manual 3A2313. For air motor repair kits, see manual
3A2315.
Air Motor and Pump for
Resin Pumpline
See air motor manual 3A2313 and pump manual
3A2315 for parts identification.
Gun
See RS gun manual 3A0232 for parts identification.
62
3A2012J
System Parts
Resin Filter
24F620
706
703
702
720
708
704
719
705
710 3
3 Press fit spring (710) to bottom of filter
707 5
bowl (701).
4 Apply thread lubricant.
4
5 Apply grease.
701
6 Apply thread sealant to all
non-swiveling pipe threads.
ti19059a
711
Ref Part
701 24C501
702 171942
703 238635
704 205447
705 --706 100509
707 104361
708 186075
710 171941
711 100040
717▲ 172479
718 GC2069
719
720
Description
BOWL, filter
HEAD, filter
VALVE, ball, carbon steel
COUPLING, hose
HOSE, nylon, 225 psi
PLUG, pipe
PACKING, o-ring
SUPPORT, filter
SPRING, compression
PLUG, pipe
TAG, warning (not shown)
FITTING, swivel, 3/8 nptm x
3/8 npsm
*
STRAINER, 100 mesh screen
155541 FITTING, swivel, elbow
Qty
1
1
1
1
7
1
1
1
1
1
1
1
1
1
▲ Replacement Danger and Warning labels, tags and
cards are available at no cost.
*
Strainer Options:
Mesh
30
60
100
200
3A2012J
2-pack
224458
224459
224468
224469
25-pack
238436
238438
238440
238442
63
System Parts
Resin Supply Hose
16M736
807
801
802
1 Apply pipe sealant to all
non-swiveling pipe threads.
803
804
805
Ref
801
802
803
804
805*
807
Part
220372
197682
114967
195151
20397-01
16M776
Description
HOSE, coupled, 6 ft
TUBE, suction
COUPLING, pipe, 1 in.
TUBE, intake
FILTER, 24 mesh, 1 in. npt
FITTING, elbow, 3/4 npsm x
1 nptf
Qty
1
1
1
1
1
1
* Other filter meshes available: 50 mesh (20397-03),
100 mesh (20397-02).
64
3A2012J
System Parts
3A2012J
65
System Parts
Catalyst Slave Pumps
926 12
910
902d
2 12 8
902 1
902b 13
902f
4
902a
901
1
1
946
1
935
6
909
932
947
1
903
1
1
902g
902f
902e 14
5
907
903a
3
6
ti19060a
911
912
913
914
6
909
915 7
916
908
6
903c
903b 3
917 8
919
920
918
9 10
920
919
5
8
Series D only
940 1
945
Series D
only
925
923
921
1
15
924
940
946 1
947 1
939
66
Apply grease to mating surfaces or threads.
4
Torque to 240 in-lb (27.1 N•m).
5
Torque to 225-275 in-lb (25.4-31.1 N•m).
1
7
Note orientation of u-cup.
8
Torque to 30-50 in-lb (3.4-5.6 N•m).
9
Clean cylinder inner diameter with soft cloth or
equivalent, prior to assembly.
10
Hand tighten cylinder (918) and bottom out to
housing (901). Back-off cylinder (918) less than 1/2
turn. Assembly pin (908).
11
Press fit bearings.
12
Torque piston rod (910) to top link (926) to
80-100 in-lb (9.0-11.3 N•m).
13
Torque to 20 - 60 in-lb (2.3-6.8 N•m).
14
Snap 902e onto 902a.
15
Orient so inside chamfer of nipple (936) is mated to
swivel (930).
11
932 1
939
3
1
External Mix Only
938
Apply thread locker to mating surfaces or threads.
936
930
924
2
assembling gauge. Attach small end of lanyard to
split ring on pin.
922
11
Apply pipe sealant to threads.
6 Loop large end of lanyard over gauge prior to
Internal Mix shown
WLE
1
1
947 1
937 1
934 1
3A2012J
System Parts
Catalyst Pumps
Description
HOUSING, slave pump
KIT, cartridge, FRP
CARTRIDGE, slave pump
BEARING, cartridge
WIPER, felt, piston rod
SEAL, snap on, cartridge
SEAL, slave pump weep
O-RING, silicone #016
VALVE, 3000 psi blow off (also
includes 903a, 903b, and 903c)
903a 224807
BASE, valve
903b 15C780
HANDLE
903c 15C972
PIN, spring
907
113641
GAUGE, pressure, fluid
124432
GAUGE, 160 psi
908
123595
PIN, quick release
909
124193
CABLE, lanyard, 5 inch
910
16N964
ROD, piston, slave pump (also
includes 919, 920, and tool
16D007)
SPRING, transfer housing
911★ 123636
VALVE, poppet
912★ 16K928
O-RING, 003, FKM
913★ 123934
914
16K960
HOUSING, transfer, etched
SEAL, radial
915★ LPA-126
GUIDE, piston
916★ LPA-127
917
16A666
CAP, transfer housing
918
16N965
CYLINDER, slave pump (also
includes 919 [Qty 2] and 920
[Qty 2])
O-RING, o-ring, silicone, 2-014
919✿‡ CJ-143
RING, backup, 0.518 ID,
920✿‡ 124061
0.053 wide
921
LPA-144
NUT, lock
922
16N976
HOUSING, inlet, slave
SEAT, ball, 7/16 dia.
923‡ --924
--BEARING, flanged, 0.375 ID
LPA-134-02 BALL, spherical
925
926
16N617
KIT, repair, catalyst pump yoke
930
114339
FITTING, union, swivel, 1/4 npt
932
123628
FITTING, adapter, 1/8 npt - #4
jic
934
297085
FITTING, elbow, 0.125 in., st
3A2012J
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Ref.
935
936
937
938
939
940
945
946
947
Part
Description
110208
PLUG, pipe, headless
94/0320-1/98 FITTING, nipple, 1/4; series D
only
124379
VALVE, check, npte x npti, 100
psi
16V706
FITTING, tee, compression, 1/4
--TUBE, polyethylene
24U857
VALVE, ball, mini; no tused on
series D
080803
VALVE, ball, 1/4 npt, ff, 316 sst;
series D only
16V703
FITTING, 1/4 npt x 3/8 tube, sst
16V704
FITTING, 1/8 npt x 1/4 tube, 90,
sst
16V705
FITTING, 1/8 npt x 1/4 tube, sst
16N741, for External Mix
Part
--24C479
------16P186
16A981
123556
16N975
16N741, for External Mix
Ref.
901
902
902a
902b†
902d†
902e✿
902f✿
902g✿
903
16N740, for Internal Mix
Qty.
16N740, for Internal Mix
Qty.
1
1
1
1
1
0.5
1 1
1
1
1
1
1
1
1
2
Installation Tools (not shown):
Foot valve seat installation tool, 16N966
Foot valve seat deluxe removal tool, 24N253 (includes
foot valve seat installation tool, 16N996)
Weep seal installation tool, 16N967 ✿
Rod Assembly Bullet Installation Tool, 16D007 ✿
--- Not for sale.
† Parts available in bearing and wiper repair kit
16P185.
‡ Parts available in foot valve repair kit 16N961.
2
2
2
2
★ Parts available in piston valve repair kit 16N962.
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
Complete rebuild kit 16N919 includes:
-Foot valve repair kit 16N961
-Piston valve repair kit 16N962
-Throat seal repair kit 16N963
-Foot ball replacement kit LPA-134-02
-Bearing with felt wiper 16P185
✿ Parts and tools available in throat seal repair kit
16N963.
1
67
System Parts
Catalyst Reservoir
16P425
1001
1002
1 Apply pipe sealant to threads.
2 Apply sticker so that the level
line is even with the 2.5 gallon
mark on tank (1001).
1 1011
1010 2
1001
1012
For outlet strainer and filter, see Carts on page 55.
Ref
1001
1002
1010
1011
1012
68
Part
--24M159
16M754
16V704
Description
Qty
TANK, gravity feed, 2.5 gallon
1
STRAINER, tank, gravity feed
1
LABEL, maximum fill line
1
FITTING, 1/8 npt x 1/4 tube, 90;
2
sst
16M738 LABEL, hazardous material
1
diamond
3A2012J
System Parts
Cart not included in kit, shown for reference only
3A2012J
69
System Parts
Hose Bundles
1105
1114
1102
1104
1109
1115
1101
1108
1106
1111
1107
1102 (Catalyst)
1105 (External Atomizing Air/
Internal Chop AAC Air)
1101 (Chopper
Air/Internal Gel AAC)
1103
1103 (Resin)
1113
ti21345a1
1104 (Internal Solvent/
External AAC)
70
3A2012J
System Parts
Hose Bundles
Ref
1101*
Part
16J767
Description
TUBE, 3/8 in., polyethylene, 28 ft
16J768 TUBE, 3/8 in., polyethylene, 38 ft
16J769 TUBE, 3/8 in., polyethylene, 53 ft
590570 TUBE, 1/2 IN., polyethylene
1102
24C540 HOSE, coupled, 1/8 in.,
3000 psi, 28 ft
24C541 HOSE, coupled, 1/8 in.,
3000 psi, 53 ft
24G429 HOSE, coupled, 1/8 in.,
3000 psi, 35 ft
1103† 240797 HOSE, coupled, 3/8 x
50 ft
277253 HOSE, coupled, 1/2 in. x
50 ft
1104
24C543 HOSE, coupled, 1/4 in.,
nylon, 28 ft
24C544 HOSE, coupled, 1/4 in.,
nylon, 53 ft
24G434 HOSE, coupled, 1/4 in.,
nylon, 40 ft
1105
--TUBE, polyethylene,
0.250 outer diameter
1106
124427 JACKET, blue scuff 22ft
124428 JACKET, blue scuff 47ft
16M599 JACKET, blue scuff 29ft
1107
16M606 JACKET, blue scuff 15ft
1108
158256 UNION, swivel
1109
277249 HOSE, coupled, 1/4 in. x
3 ft, 4000 psi
1110◆ 744
GUIDE, roving, hose
1111▲ 16D659 LABEL, warning, hose
bundle
1112
114271 STRAP, retaining
1113
123379 FITTING, reducer,
3/8 nptx1/4 npt
162449 FITTING, nipple, reducing
1114
520563 TUBE, 3/8 in., polyethylene
1115
16U657 UNION, 1/2 in. x 3/8 in.
OD tubing
Quantity
16M584, 16M585,
16M587, 16M588,
16M590, 16M591,
50 ft 16M586, 25 ft,
25 ft, 16M589, 35 ft,
35 ft,
16M583, 50 ft
50 ft, internal external 25 ft, internal external 35 ft, internal external
gel
gel
gel
gel
gel
gel
chop
chop
chop
1
1
1
53 ft
28 ft
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
53 ft
1
28 ft
2
1
1
1
1
1
1
1
28 ft
2
38 ft
38 ft
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2.5 ft
1
2.5 ft
1
2.5 ft
1
1
1
*
†
◆ Not shown.
The 25 ft and 35 ft hose bundles come with 50 ft of resin
hose. The extra resin hose is coiled at the factory and is
part of the pressure surge suppression system.
1
1
1
53 ft
1
1
▲ Replacement Danger and Warning labels, tags and cards
are available at no cost.
3A2012J
35 ft
1
1
1
1
1
1
1
1
1
1
1
1
Series C and prior chop hoses use 16J769. Series D or
later chop hoses are shown in the table.
71
System Parts
Accessory Parts
Heater Kits
1202f
1202e
1202d
1
Use 1/2-14 npt x 3/8-18 npt fitting for gel systems.
Use 1/2-14 npt x 1/2-14 npt fitting for chop systems.
2
Reducing pipe nipple (1209) can be used instead of elbow
fitting (1214).
16N014 and 16N015 Kits
1206
1205
1204
1201
1202d
1202c
1202b
1215 1210
1213
1210
1202a
1211
1204
1
1
1214
2
1213
1203
ti21346a
1210
16N0169, 16N017, 16N018, and 16N019 Kits
1202f
1202e
1202d
1202a
1203
1215
1204
1202d
1202c
1202b
1202a
1213
1
1214
1
1210
1208
1213
1211
72
ti21347a
3A2012J
System Parts
Heater Kits
Ref
1201*
1202*
1202a†
1202b†
1202c†
1202d†
1202e†
1202f†
1203*
1204*
1205*
1206*
1208*
1209*
1210*
1211*
Part
16N013
16P291
19891-00
19892-00
115211
113962
100018
100321
100058
110755
100131
100015
162449
159239
158491
H55003
1212*
1213*
--155470
1214*
217430
1215
245848
245863
245867
245869
226819
226816
*
Description
BRACKET, heater
KIT, pipe clamp
CLAMP, pipe, set
PLATE, cover, clamp
SCREW, cap, hex hd
WASHER, hardened
WASHER, lock, spring
NUT
SCREW, cap, hex head
WASHER, plain
WASHER, lock
NUT, hex, mscr
NIPPLE, reducing
NIPPLE, pipe, reducing
NIPPLE
HOSE, coupled, 5600
psi
TAPE, PTFE
SWIVEL, union, 90°; 1/2
x 1/2 npt
SWIVEL, union, 90°; 1/2
x 3/8 npt
HEATER, viscon HP
HEATER, viscon HP
HEATER, viscon HP
HEATER, viscon HP
HEATER, viscon, 240
volt
HEATER, viscon, 120
volt
16N014,
120v, FM
★
1
2
1
1
2
4
2
2
4
8
4
4
1
1
2
1
Quantity
16N015,
16N016,
16N017,
16N018,
16N019,
240v, FM
120v,
240v,
120v, non- 240v, non★
hazardous hazardous hazardous hazardous
1
1
1
1
1
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
4
4
4
4
4
2
2
2
2
2
2
2
2
2
2
4
4
4
4
4
8
8
8
8
8
4
4
4
4
4
4
4
4
4
4
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
1
1
1
1
1
1
2
1
2
1
2
1
2
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
Items are available in heater hardware kit 16N119.
† Parts available in pipe clamp kit 16P291.
★ Heaters can be disassembled to remove cured material.
3A2012J
73
System Parts
Solvent Pressure Pot Kits
ASME Pressure Pots, 2-gallon 16M893 and 5-gallon 16M894
2 1307
1311 3
1306
2 1310
1304 2
1305 2
2 1309
1302 2
2 1303
1301 1
1 To assemble strainer (1311), remove the dip tube from tank (1301). Slide
strainer onto bottom end of dip tube. Hold strainer in place while
positioning dip tube. Strainer should be secure on ube and pressed to
bottom of tank. Tighten dip tube in place. Strainer not shown.
2 Apply pipe sealant.
3 Clamp ground cable (1311) to handle on tank (1101). Ground cable not
shown.
Ref
1301
1302
1303
1304
1305
1306
1307
1308
1309
1310
1311
74
Part
20324-00
Description
TANK, solvent, 2 gallon
(assembly 16M893 only)
20324-01
TANK, solvent, 5 gallon
(assembly 16M894 only)
16D939
FITTING, nipple, reducing
11021-23
PLUG, pipe, 1/4
18470-05
VALVE, ball, 2-way, 1/4nptf
RM-856-04 FITTING, elbow, 1/4 nptm x
1/4 nptm
20655-04
FITTING, elbow, 3/8 nptm x
3/8 tube
103347
VALVE, safety, 100 psi
21035-00
STRAINER, pick-up, material
21462-01
FITTING, adapter, 1/4 nptm x
3/8 nptf
3165
VALVE, ball, 2-way,
3/8 female, 3/8 male
17440-00
CLAMP, grounding
Qty
1
1
1
1
1
1
1
1
1
1
1
1
3A2012J
System Parts
ASME and CE-Approved Pressure Pots, 16M874 and 16M875
1 1411
1 1406
1 1410
1403
1408 1
1402
1409 1
1 1408
1 1412
1401
1406 1
1 Apply pipe sealant.
2 Clamp ground cable (1423) to handle on
1404
tank (1401). Ground cable not shown.
3 Must be installed on the outlet side. The
1401
1405 3
outlet is the port without the cross hole.
1414
1401
Ref
1401
1402
1403
1404
1405
1406
1407
1408
1409
1410
1411
1412
1413
1414
Part
236086
Description
Qty
TANK, pressure assy, 2 gal.
1
(assembly 16M874 only)
236087 TANK, pressure assy, 5 gal.
1
(assembly 16M875 only)
165053 PACKING, o-ring
1
188880 PLUG, lid
1
188784 NUT, jam, hex
1
171976 TUBE
1
(assembly 16M875 only)
185531 TUBE, siphon (assembly
1
16M874 only)
--BUSHING, hex, 3/8npt x 1/4npt,
2
male/female
111763 FITTING, elbow, 1/4 npt
1
18470-05 VALVE, ball, 2-way, 1/4nptf
2
--FITTING, nipple, reducing
1
108673 TEE, street
1
103347 VALVE, safety, 100 psi
1
--FITTING, connector, male,
1
3/8 npt
210575 CAP, filler (assembly 16M875
1
only, not shown)
176347 LABEL, identification
1
3A2012J
Ref
Part
1415 --1416▲ 175078
1421 308370
1423 17440-00
1424 171988
Description
LABEL, designation
LABEL, warning
MANUAL
CLAMP, grounding
O-RING (for filler cap,
item 1413, not shown)
Qty
1
1
1
1
1
▲ Replacement Danger and Warning labels, tags and
cards are available at no cost.
75
System Parts
Solvent Diaphragm Pumps
2-gallon 16M560 and 5-gallon 16M561
1505
1502,1503
1504
1501,1503
Base System shown for reference only
Ref Part
1501 16M559
1502 16M652
16M651
1503 16M769
1504 --1505 16N891
16N892
76
Description
PUMP, solvent, FRP, flush
TANK, solvent, 2.5 gal assembly
(assembly 16M560 only)
TANK, solvent, 5 gal assembly
(assembly 16M561 only)
KIT, pump fasteners
TUBING, nylon, round
KIT, pick-up tube, 2.5 gallon
(16M560 only)
KIT, pick-up tube, 5 gallon
(16M561 only)
Qty
1
1
1
1
3
1
1
3A2012J
System Parts
DataTrak Upgrade Kit
16M881
1602
1602
Ref
Part
1601 * 24A354
1602 24A576
Description
SMART AIR VALVE (not shown)
DATATRAK CONVERSION KIT
Qty
1
1
* See FRP air motor manual.
3A2012J
77
System Parts
Carts for 55 Gallon Barrel,
16M896
1717
1706
1712
1704, 1705, 1718
1718 1705
1704
1701
1716
WLE
1711
1707
1708
1714
1703
1715
1713
Ref
1701
1702
1703
1704
1705
1706
1707
1708
1709
1710
1711
1712
1713
1714
1715
1716
1717
1718
Part
--16P134
16M465
113962
100321
16N977
100521
100023
104008
GC2096
16N978
100424
116645
100696
100052
124291
258982
100018
1708
1709
1710
1702
Description
PLATE, 55 gal drum
CASTER, rigid
CASTER, locking
WASHER, hardened, sae
NUT
BRACKET, drum cart
SCREW, cap hex head
WASHER, flat
WASHER, lock, spring
NUT, hex, standard, 5/16-18
BRACKET, handle, drum cart
SCREW, cap, hex head
SCREW, cap, hex head
WASHER, wrought
WASHER, lock
PIN, spring
HANDLE, cart
WASHER, lock, spring
Qty
1
2
2
6
4
2
8
16
8
8
1
2
1
1
1
1
1
4
--- Not for sale.
78
3A2012J
System Parts
Roving Box Bracket
16M961
1802
1801
ti18525b
1803
1807†
1804,1805
1806
Ref
1801
1802
1803
1804
1805
1806
1807†
Part
16M619
16M622
122741
104123
112248
16M965
15J889
NOTE: Second roving box shown for reference only to illustrate installation.
Description
BRACKET, roving
BRACE, roving box
SCREW, hex cap, 1/4 x 0.50
WASHER, lock, spring
NUT, hex
CLAMP, u-bolt
SCREW, hex
Qty
1
1
2
2
2
2
2
† Long bolts are only used if two kits will be installed
side by side.
3A2012J
79
System Parts
Extension Hoses
1906
Gel Hose
1904
1905
1901
1907
1903
1913
1902
1904
1906
Chop Hose
1905
1907
1902
1913
1903
ti21348a
1903, 1907 (Resin)
1904, 1912 (Internal Solvent/
External AAC Air)
1902, 1909 (Catalyst)
1905, 1911 (External Atomizing Air/
Internal Chop AAC Air)
1901, 1910 (Chopper Air/
Internal Gel AAC)
Ref
1901
Part
16J766
590570
24J730
Description
TUBE, 3/8 in. polyethylene, 25 ft
TUBE, 1/2 in. polyethylene
1902
HOSE, coupled, 1/8 in., 3000 psi,
25 ft
1903 240796 HOSE, coupled, 3/8 x 25'
16M731 HOSE, coupled, 1/2 in. x 25',
4000 psi
1904 24J731 HOSE, coupled, 1/4 in., nylon,
25 ft
1905 --TUBE, polyethylene, 1/4 in. OD
1906 124427 JACKET, blue scuff, 22 ft
1907 158256 UNION, swivel
1908 744
GUIDE, roving, hose (not shown)
1909 123553 FITTING, nipple, #4 JIC
1910* 123554 COUPLER, 3/8 in. OD tubing
16U953 COUPLER, 1/2 in. OD tubing
1911 123789 COUPLER, 1/4 in. OD tubing
1912 123552 FITTING, nipple, 1/8 npt
1913▲ 16D659 LABEL, warning, hose bundle
16M712,
for chop systems
▲ Replacement Danger and Warning labels, tags and
cards are available at no cost.
80
25.5 ft
1
Quantity
16M718,
for internal gel
1
16M719,
for external gel
1
1
1
1
1
1
1
25 ft
1
1
1
25 ft
1
1
1
1
1
1
1
1
*
1
1
1
1
1
1
1
1
Series C and prior chop hoses use 123554. Series D or
later chop hoses are shown in the table.
3A2012J
Dimensions
Dimensions
Cart and Boom
ti18526b
B
A
Top View
F
C
¡
¡
E
*
Ref.
A
(Max Width)
B
(Max Height)
C
(Max Depth)
E
(Radius)
F
(Radius)
Description
144 in.
(3658 mm)
100 in.
(2540 mm)
192 in.
(4877 mm)
144 in.
(3658 mm)
72 in.
(1828 mm)
Rotate unit to fits cart and boom system through a 3 ft 6 in. wide door, with a 9 in. jamb width.
** Height with boom installed. Height of unit without the boom is 83 in. (2108 mm).
3A2012J
81
Dimensions
Cart Only
B
C
A
Ref.
Cart Only
A
(Max Width)
29.5 in.
(749 mm)
B
(Max Height)
47.75 in.
(1213 mm)
C
(Max Depth)
32.5 in.
(826 mm)
ti18496b
Wall/Pole Mount
B
A
Ref.
Wall/Pole Mount
A
(Max Width)
39.0 in.
(991 mm)
B
(Max Height)
46.6 in.
(1183 mm)
C
(Max Depth)
32 in.
(813 mm)
ti18524d
C
82
3A2012J
Technical Data
Pumpline Wall Mounting Bracket Dimensions
The pumpline bolts directly to this mounting plate.
3.52 in.
(89.4 mm)
WLD
10.1 in.
(257 mm)
Four 0.60 in. (15 mm)
mounting holes
Technical Data
System Technical Data
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . 13:1 Systems: 1300 psi (9 MPa, 90 bar)
17:1 Systems: 1700 psi (11.9 MPa, 119 bar)
Maximum air inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7.0 bar)
Maximum air inlet pressure to ASME solvent pressure pots . . . 100 psi (0.7 MPa, 7.0 bar)
Typical flow rate of pattern guns . . . . . . . . . . . . . . . . . . . . . . . . Refer to RS Gun manual. See Related Manuals, page 3.
Maximum fluid temperature (Models with RS Gun) . . . . . . . . . . 100°F (38°C)*
Maximum fluid temperature (Models without RS Gun) . . . . . . . 160°F (71°C)*
A component (catalyst) inlet size . . . . . . . . . . . . . . . . . . . . . . . . 3/8 in. tube
B component (resin) inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5/16-12 UN-2A male
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless steel, carbide, UHMWPE, PTFE, and acetal.
Resin wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Pumpline Technical Data, page 84
Catalyst wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Catalyst Pump Technical Data, page 84
*
Maximum fluid temperature rating determined by
lowest rated component in system.
3A2012J
83
Technical Data
Pumpline Technical Data
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . 13:1 Systems: 1300 psi (9 MPa, 90 bar)
17:1 Systems: 1700 psi (11.9 MPa, 119 bar)
Maximum air inlet pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7.0 bar)
Minimum air inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 psi (0.07 MPa, 0.7 bar)
Maximum ambient air temperature . . . . . . . . . . . . . . . . . . . . . . . 120°F (49°C)
Maximum cycle rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 cpm
Air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Technical Data in air motor manual 3A2315.
Fluid output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13:1 Systems: 1.5 gpm (free flow at 70 cpm)
17:1 Systems: 1.1 gpm (free flow at 70 cpm)
Maximum fluid temperature
160°F (71°C)
NOTE: System rating is lower than this due to other, lower-rated
components.
Stroke length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 in. (51 mm)
Sound data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Technical Data in air motor manual 3A2315.
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless steel, tungsten carbide with 6% nickel,
UHMWPE, PTFE,
LW100C displacement pump only: Also includes carbon steel
Catalyst Pump Technical Data
Maximum fluid working pressure
Internal catalyst pump version. . . . . . . . . . . . . . . . . . . . . . .
External catalyst pump version . . . . . . . . . . . . . . . . . . . . . .
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wetted parts**. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2000 psi (14.0 MPa,140 bar)
90 psi (0.63 MPa, 6.3 bar)
3.5 lb (1.6 kg)
301, 303, 304, 316, and 17-4 PH grades of stainless steel,
silicon nitride, acetal, perfluoroelastomer, PE, PTFE, UHWMPE,
polypropylene
** Series A and B systems (built prior to April 2013) have non-metallic nylon catalyst tube fittings. To covert your system to stainless steel fittings, see the FRP Proportioner manual 332451.
Whip Hose Technical Data
Hose bundles maximum fluid working pressure and wetted
materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Catalyst hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/2 in. resin hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3/8 in. resin hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solvent/AAC air hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3/8 in. OD air hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/4 in. OD atomizing/AAC air hose . . . . . . . . . . . . . . . . . . .
1/2 in. OD air hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3000 psi (21.0 MPa, 210 bar); PTFE
4000 psi (28.0 MPa, 280 bar); nylon
3300 psi (23.1 MPa, 231 bar); nylon
225 psi (1.6 MPa, 16 bar); nylon
125 psi (0.9 MPa, 9 bar); PET
125 psi (0.9 MPa, 9 bar); PET
250 psi (1.7 MPa, 17 bar); PET
Resin Pump, Catalyst Pump, Solvent Pump, and Heater Technical Data
See component manuals listed on page 3 for technical data.
84
3A2012J
Technical Data
3A2012J
85
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be 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 general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
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 claimed defect. 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 include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, 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.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English. MM 3A2012
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2012, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised June 2014

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