Graco 3A2012S, FRP Proportioner Instructions

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Instructions - Parts

FRP Proportioner

3A2012S

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 85 for maximum working pressure and other

specifications. For patent information, see www.graco.com/patents.

FIRE AND EXPLOSION HAZARD

WARNING

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

Cart and Boom System ti18524d

Wall Mount System ti18496b

Cart System

II 2 G Ex h T5 Gb

2

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 . . . . . . . . . . 37

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Catalyst Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Resin Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

General Information . . . . . . . . . . . . . . . . . . . . . . 41

Disconnect the Displacement Pump . . . . . . . . . 41

Reconnect the Displacement Pump . . . . . . . . . 42

Disconnect the Air Motor . . . . . . . . . . . . . . . . . . 44

Reconnect the Air Motor . . . . . . . . . . . . . . . . . . 44

Replace Pumpline . . . . . . . . . . . . . . . . . . . . . . . 46

Repair Catalyst Pump . . . . . . . . . . . . . . . . . . . . 47

System Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Carts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Wall or Pole Mount Kit, 16N918 . . . . . . . . . . . . 58

Boom, 16N761 . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Air Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Slave Pump Linkage, 16P125 . . . . . . . . . . . . . . 61

Resin Pumplines . . . . . . . . . . . . . . . . . . . . . . . . 62

Air Motor and Pump for

Resin Pumpline . . . . . . . . . . . . . . . . . . . . . . 64

Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Resin Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Resin Supply Hose . . . . . . . . . . . . . . . . . . . . . . 66

Catalyst Slave Pumps . . . . . . . . . . . . . . . . . . . 68

Catalyst Reservoir . . . . . . . . . . . . . . . . . . . . . . . 70

Hose Bundles . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Hose Bundles . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Accessory Parts . . . . . . . . . . . . . . . . . . . . . . . . . 74

Heater Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Solvent Pressure Pot Kits . . . . . . . . . . . . . . . . . 76

Solvent Diaphragm Pumps . . . . . . . . . . . . . . . . 78

DataTrak Upgrade Kit . . . . . . . . . . . . . . . . . . . . 79

Carts for 55 Gallon Barrel, 16M896 . . . . . . . . . 80

Roving Box Bracket . . . . . . . . . . . . . . . . . . . . . . 81

Extension Hoses . . . . . . . . . . . . . . . . . . . . . . . . 82

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Cart and Boom . . . . . . . . . . . . . . . . . . . . . . . . . 83

Cart Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Wall/Pole Mount . . . . . . . . . . . . . . . . . . . . . . . . 84

Pumpline Wall Mounting Bracket Dimensions . . 85

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 88

3A2012S

Related Manuals

Related Manuals

Manuals are available at www.graco.com. Component manuals in English:

Manual Description

3A0232 RS ™ Gun Instructions-Parts

3A2313 U-Cup Displacement Pump

312792 Merkur Displacement Pump

3A2315 NXT ® Air Motor for FRP

332451 FRP Stainless Steel Fitting Kit

308981 Air Operated Diaphragm Pumps

309524 Viscon HP Heater Instructions

307363 Viscon ® Heater Instructions

313541 DataTrak ™ Conversion Kit Instructions

308370

ASME and CE-Approved Pressure Pot

Instructions (Solvent Flush Pressure Pot)

307273 Fluid Outlet Filter

407019 Chop Cart Legs Kit

407020 55 Gallon Drum Kit

407021 Roving Box Bracket Kit

407022 Deluxe Inlet Seat Removal Tool

Manual Description

407023 5 Gallon Catalyst Reservoir Kit

407024 Boom Kit

407025 DataTrak ™ Upgrade Kit

407026 Wall or Pole Mount Kit

407027 Linkage Replacement Kit

407028 Resin Pump Connecting Kit

407031 Diaphragm Pump Solvent Flush Kit

407032

Non-CE Approved Solvent Pressure Pot

Kits

407033

ASME and CE-Approved Pressure Pot

Kits

407042 Heater Kits

Agency Approvals

FRP proportioner systems are approved for use in hazardous locations when the base model, all accessories, all kits, and all wiring meet local, state, and national codes.

Base FRP System with no accessories*

Accessories

* Solvent pots do not affect Atex rating.

 CE and or EX approved.

II 2 Gc T5

See accessory manuals listed in Related Manuals section for approvals.

3A2012S 3

4

Models

Models

Ratio

13:1

17:1

9:1

Internal or

External

Mix

Internal Mix

External

Mix

Internal Mix

External

Mix

Internal Mix

Gel or

Chop

Gel

Chop

High Flow

Chop

Gel

Chop

Gel

Gel

Chop

No Cart

Part No.

Hose

Length ft (m)

16R065  25 (7.6)

Part No.

16R002 

Cart

Hose

Length ft (m)

25 (7.6)

Cart, Mast, and Boom

Part No.

Hose

Length ft (m)

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 

16R135 

---

25 (7.6)

16R050 

16R123 

---

25 (7.6)

16R062 

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 

24W435 

---

25 (7.6)

16R120 

24W432 

---

25 (7.6)

16R132 

24W438 

---

25 (7.6)

24W436  35 (10.7) 24W433  35 (10.7) 24W439  35 (10.7)

24W437  50 (15.2) 24W434  50 (15.2) 24W440  50 (15.2)

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  ---

16R300

16R303

16R306

16R309

25 (7.6)

35 (10.7)

50 (15.2)

---

16R301

16R304

16R307

16R310

25 (7.6)

35 (10.7)

50 (15.2)

---

16R302

16R305

16R308

16R311

25 (7.6)

35 (10.7)

50 (15.2)

---

3A2012S

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.

Solvent Flush Diaphragm Pumps

Part Description

16M560 2 Gallon Solvent Flush Diaphragm Pump

16M561 5 Gallon Solvent Flush Diaphragm Pump

Solvent Flush Pressure Pots

Part

16M874

Description

2 Gallon, ASME and CE-approved, Solvent

Flush Pressure Pot

16M875

5 Gallon, ASME and CE-approved, Solvent

Flush Pressure Pot

16M893 2 Gallon, ASME Solvent Flush Pressure Pot

16M894 5 Gallon, ASME Solvent Flush Pressure Pot

Heaters

Part

16N014 

Description

120V Viscon Heater, for hazardous locations

16N015

16N016

16N017

16N018

16N019

240V Viscon Heater, for hazardous locations

120V Viscon Heater, for hazardous locations and explosive atmospheres

240V Viscon Heater, for hazardous locations and explosive atmospheres

120V Viscon Heater, for non-hazardous locations

240V Viscon Heater, for non-hazardous locations

Heaters can be disassembled to remove cured material.

Extension Hoses

Part

16M712

Description

25 ft Extension Hose Bundle for Chop Systems

16M718

16M719

25 ft Extension Hose Bundle for Internal Gel

Systems

25 ft Extension Hose Bundle for External

Gel Systems

55 Gallon Barrel Carts

Part Description

16M896 55 Gallon Barrel Cart

Roving Box Bracket

Part Description

16M961 Roving Box Bracket Kit

DataTrak Upgrade

Part Description

16M881 DataTrak Upgrade Kit

5 Gallon Catalyst Reservoir

Part Description

24M501 5 Gallon Catalyst Reservoir Kit

Wall Mounting

Part Description

16N918 FRP Pole or Wall Mount Kit

Pump Connecting Kits

Part Description

16N242 17:1 Pump Connecting Kit

16N243 13:1 Pump Connecting Kit

3A2012S 5

6

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.

3A2012S

3A2012S

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.

7

8

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.

3A2012S

Polyester Resins and Gel-Coats

Important Two-Component Material Information

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.

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.

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.)

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.

Keep Resin and Catalyst

Components Separate

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.

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.

3A2012S 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, all kits, and all wiring meet local, state, and national codes.

10 3A2012S

Component Identification

Component Identification

F

D

N

L

B

A

C

E

Cart system shown with solvent flush diaphragm pump and external mix gel gun

M

H

WLF

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)

* Internal mix systems only.

3A2012S

H Air Control Panel

J Heater (not shown)

K Grounding Wire (not shown)

L Hook support for resin hose coil

(25 ft and 35 ft hose bundles only)

M Spray gun

N Air/Water Separator (customer supplied)

11

Component Identification

Air Control Panel

Air inlet (AA): from air line.

Air regulator 1 (AB): controls air to resin pump.

Air outlet 1 (AC): air line to resin pump.

Air pressure gauge 1 (AD): indicates air pressure to resin pump.

Air regulator 2 (AE): for external mix guns only: controls catalyst atomization air. For internal mix guns only: controls solvent flush pressure.

Air outlet 2 (AF): for external mix guns only: catalyst air line to spray gun. For internal mix guns only: to solvent pump.

Air pressure gauge 2 (AG): indicates regulator 2 air pressure.

Air regulator 3 (AH): controls Air Assist Containment ™

(AAC ™ ) air to spray gun.

Air pressure gauge 3 (AK): indicates AAC air pressure.

Air outlet 3 (AM): AAC air line to spray gun.

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 Shutoff valve (AP): shuts off air to entire system.

FRONT REAR

AH

AC

AM

AK

AE

AD

AF

AP

AG AB

F IG . 1: Air Control Panel Components ti21338a

Air Outlet Fitting

Details

Air Outlet 2 (AF)

Air Outlet 3 (AM)

Air Outlet 4 (AN) 

Internal Chop

3/8 tube

1/4 tube

1/2 tube

External Chop

1/4 tube

1/8 npt

1/2 tube

 Includes a 1/2 to 3/8 reducer to adapt to older chop hose bundles

AN

Internal Gel

3/8 tube

3/8 tube

Plugged

12

AA ti21339a

External Gel

1/4 tube

1/8 npt

Plugged

3A2012S

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.

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

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 Data-

Trak controls and indicators.

R

P

P1

N

F IG . 2

M ti18499c

S

3A2012S 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.

Pivot point (V2): when pump is moved to adjust ratio, this point stays stationary.

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.

Fluid pressure gauge (X): indicates catalyst fluid pressure.

Fluid inlet (Y): fluid inlet from the catalyst reservoir.

Fluid Inlet Ball Valve (Y2): controls flow of catalyst to the catalyst pump.

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.

Fluid outlet (Z1): fluid out to the gun.

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.

NOTE: For Wall Mount Units, the nuts and Ferrules for the compression fitting have been removed, bagged, and attached to the slave pump for shipping.

Z2

Z

Z3

Y

Y2

U

V1

U

Z2 ti21340a

Z1

Z ti21342a

F IG . 3: Catalyst Pump Components

W

X

V2

Z3

14 3A2012S

Component Identification

Solvent Flush Systems

Solvent Flush Diaphragm Pump

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.

1/4 npt(f)

Air Inlet

3/4 npt(f) Fluid

Outlet

Solvent Flush ASME and CE-Approved Pressure Pot

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.

Air Inlet Fill Cap Fluid Outlet

3/4 npt(f) Fluid Outlet

F IG . 4: Solvent Pump Components

3/4 npt(f)

Fluid Outlet ti9078a1

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 ti18531a ti18530a

3A2012S 15

Setup

Setup

System Mounting (Wall Mount

Systems Only)

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.

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.

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.

Location Requirements

Refer to

Dimensions , page 83, for mounting and clear-

ance dimensions.

Cart Mount Systems

• Position the FRP proportioner so the air controls and catalyst ratio adjustment arm are easily accessible.

• 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.

ti18527d

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 3A2012S

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.

Setup

3A2012S 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 3A2012S

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.

Chain

Spring

Roving Guides

Deflector Plates ti18532b

7. 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.

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).

ti18525b

3A2012S 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

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.

General Grounding Guidelines

Pump: use ground wire and clamp (supplied). Connect ground clamp to a true earth ground.

Air and fluid hoses: use only electrically conductive hoses.

Spray gun: ground through connection to a properly grounded fluid hose and pump.

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.

Ground screw

F IG . 5: Ground Wire ti18454a

Grounding wire

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 dia-

phragm 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 3A2012S

Setup

Connect Fluid and Air Lines

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.

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

F IG . 6: Hose End Diagram

AH

FRONT

AK

AE

AD

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

F IG

. 2 on page 13 and F IG . 7.

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.

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 sol-

vent pump air inlet. See F IG . 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.

AC

REAR

AM

AF ti21338a

AP

AG AB

F IG . 7: Air Control Panel Components

Air Outlet Fitting

Details

Air Outlet 2 (AF)

Air Outlet 3 (AM)

Air Outlet 4 (AN) 

Internal Chop

3/8 tube

1/4 tube

1/2 tube

External Chop

1/4 tube

1/8 npt

1/2 tube

 Includes a 1/2 to 3/8 reducer to adapt to older chop hose bundles.

3A2012S

AN

Internal Gel

3/8 tube

3/8 tube

Plugged

AA ti21339a

External Gel

1/4 tube

1/8 npt

Plugged

21

Setup

Resin Pump and Optional Heater Connections Catalyst Pump Fluid Connections

NOTE:

See F IG . 3 on page 14.

11. Verify the pressure relief/recirculation valve (W) is set to pressure relief (knob is horizontal).

M

R ti18499c

P

P1

N

F IG . 8

S

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.

W ti21343a

F IG . 9: Catalyst Pump Pressure Relief Valve

12. Connect the catalyst line from the gun hose bundle to the catalyst outlet (Z1).

22 3A2012S

Setup

Solvent Flush Connections (if applicable)

NOTE:

See Solvent Flush Systems

component identi-

fication 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 contaminat-

ing 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.

3A2012S 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.

Boom Operation

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. ti18532b

The height of the boom can be adjusted by adjusting which link in the chain is secured to the boom arm.

1. Close the main air supply ball valve.

NOTICE

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.

F IG . 10

3. Disengage the trigger lock on the gun. See F IG . 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.

F IG . 11

24 3A2012S

5. Engage trigger lock.

Operation

8. After the pressure is fully relieved, turn the pressure relief/recirculation valve to dispense position.

F IG . 12

6. Turn catalyst pump pressure relief/recirculation valve to the pressure relief position.

F IG . 15

F IG . 13

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.

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.

10. See the gun manual listed on page 3 for shutdown

and maintenance procedures.

11. Perform the scheduled maintenance items listed on

page 37.

F IG . 14

3A2012S 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 proce-

dures 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 3A2012S

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.

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.

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.

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.

F IG . 16

3A2012S 27

Operation

5. Verify the pressure relief/recirculation valves on the resin pump is set to the pressure relief/recirculation position.

10. Turn the catalyst pump pressure relief/recirculation valve to the dispense position.

F IG . 20

F IG . 17

6. Turn the main air supply pressure regulator fully counter-clockwise to relieve pressure and set to zero pressure. See F IG . 18.

7. Turn the main air supply ball valve to the open position. See F IG . 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 F IG . 18.

11. Disengage the trigger lock on the gun. See F IG . 21.

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.

F IG . 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 F IG . 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.

F IG . 21

F IG . 19

28 3A2012S

13. Turn the main air supply ball valve to the closed position.

F IG . 22

14. Turn the catalyst pump pressure relief/recirculation valve to the pressure relief position. This will relieve any built up pressure.

F IG . 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.

F IG . 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.

3A2012S

Operation

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 con-

tainers, 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 3A2012S

Spray

Operation

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

pro-

cedure 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.

F IG . 26

5. Turn the catalyst pump pressure relief/recirculation

valve to the dispense position. See F IG . 27.

6. Bring catalyst pump fluid outlet line to dispensing

pressure (see F IG . 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.

F IG . 27

F IG . 25

3A2012S 31

Operation

7. Turn the main air supply ball valve to the open posi-

tion. See F IG . 28.

8. Slowly turn the main air supply pressure regulator clockwise until the main air supply pressure gauge

reads the desired pressure. See F IG . 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

F IG . 28

9. Disengage trigger lock on the gun. See F IG . 29.

10. Pull trigger to begin dispensing. See F IG . 29.

F IG . 29

F IG . 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.

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 3A2012S

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 F IG . 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

GT BT

CF; See Details at right.

RK

PF

CF

TI8622b

Setup Mode

CD

TI11883a

CC

*CB

RK

RT UT

DT

ST

PF

F IG . 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 36)

CF Display

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.)

CA

TI8623b

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)

* 9:1 pump setting is 100cc (for 2 in stroke).

13:1 pump setting is 80cc (for 2 in stroke).

17:1 pump setting is 60cc (for 2 in. stroke).

3A2012S 33

Operation

Setup Mode

1. See F IG . 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 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

1. See F IG . 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.

AP

NOTE: When runaway, E1, E2, and E5 error options are enabled, a  will appear on the setup screen. See F IG .

31.

3. Move the cursor to the E5 error enable option field, then press once more to exit Setup mode.

F IG . 32. Solenoid Release Button

J ti11902a

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) F IG . 31).

34 3A2012S

Operation

Prime/Flush

1. See F IG . 31. To enter Prime/Flush mode, press any 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

Counter/Totalizer

. The Prime/Flush symbol will disappear from the display and the LED will stop flashing.

See F IG . 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 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.

Display

See F IG . 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.

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 F IG . 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.

3A2012S 35

Operation

Symbol

Table 1: Diagnostic Codes

Runaway

(DataTrak only)

Diagnosis

Pump running faster than set runaway limit.

Cause

• Increased air pressure.

• Increased fluid output.

• Exhausted fluid supply.

36

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 37.

E-4

E-4

E-5

E-6

Service

Component 1

(units with runaway protection only)

Disconnected

Solenoid

(units with runaway protection only)

Service

Component 2

Blown Fuse

Problem with stopping runaway.

Solenoid is disconnected.

Solenoid is not engaging piston cup.

Problem with sensing valve movement.

Fuse is blown. Replace fuse;

see page 37.

• Damaged solenoid.

• Damaged valve carriage.

• Runaway (RT, F

IG

. 31) protection may be enabled with pump that is not equipped with a runaway solenoid valve. Enter setup screen and disable runaway protection.

• Solenoid unplugged.

• Damaged solenoid wires.

• Bracket and solenoid not tight against air valve housing.

• Sensors unplugged.

• Sensors mounted incorrectly.

• Damaged sensors.

• Damaged valve carriage.

• Faulty solenoid or solenoid wiring.

• Extreme temperatures

(above 140°F [60°C]).

• Runaway (RT, F IG . 31) protection may be enabled with pump that is not equipped with a runaway solenoid valve. Enter setup screen and disable runaway protection.

3A2012S

Operation

Replace DataTrak Battery or Fuse

The battery and fuse must be replaced in a non-hazardous location.

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

Use only a Graco-approved replacement fuse. Order

Part 24C580.

Replace Battery

1. Unscrew cable from the back of the reed switch assembly. See F IG . 33.

2. Remove the cable from the two cable clips.

4. Remove two screws on back of module to access battery.

5. Disconnect the used battery and replace with an approved battery. See F IG . 34.

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.

Solenoid Cable

Connection

Fuse

Sensor Cable

Connection ti11992a

F IG . 33. Disconnect DataTrak

3. Remove DataTrak module from bracket. Take module and attached cable to a non-hazardous location.

Battery

F IG . 34. DataTrak Battery and Fuse Location ti11994a

3A2012S 37

Maintenance

Maintenance

Task

Inspect pump wetcup and fill with TSL and remove any particles or residue

Remove resin pump outlet filter and flush debris

Inspect hoses for wear or damage and replace immediately if found

Remove catalyst reservoir filter and clean with solvent

Replace catalyst reservoir filter

Flush system

Schedule

Daily

Daily

Weekly

As needed

As needed

As needed

Components

See component manuals listed on page 3 for mainte-

nance schedules and procedures for each component.

38 3A2012S

Troubleshooting

Troubleshooting

Follow Pressure Relief Procedure and Shutdown on page 24 before checking or servicing the equip-

ment.

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 68 for parts identification.

Problem

Pressure loss on up stroke.

Pressure loss on up stroke and down stroke.

Pressure not building on up stroke.

Pressure not building on down stroke.

Leakage from cartridge housing.

Pressure being relieved through relief valve or check valve at a low pressure.

Pump will not prime.

Excessive weepage

Cause Solution

Worn transfer housing seal.

Worn transfer housing seat.

Worn weep seals.

Blow off valve spring is wearing out.

Replace transfer housing seal.

Replace transfer housing.

Replace weep cartridge.

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.

Damaged transfer housing seat.

Scratched inlet valve.

Replace transfer housing.

Replace inlet valve.

Loose cartridge housing.

Loose bearing.

Relief valve or check valve has a weak spring.

Tighten cartridge housing.

Tighten bearing.

Replace relief valve or check valve.

Fluid inlet ball valve is closed.

Missing snap-on seal retainer

Open fluid inlet ball valve.

Remove cartridge and install

Worn or damaged snap-on seal retainer Remove and replace

Resin Pump

See Resin Pumplines on page 62 for parts identification.

Problem

Does not operate.

Stall on bottom of stroke.

Cause Solution

Valve closed or clogged.

Clear air line; increase air supply. Check that valves are open.

Fluid hose or gun obstructed.

Dried fluid on displacement rod.

Clean hose or gun.*

Clean rod; always stop pump at bottom of stroke; keep wet-cup filled with Throat Seal Liquid (TSL).

Clean or repair air motor. See air motor manual.

Air motor parts dirty, worn, or damaged.

Runaway error on DataTrak tripped (if DataTrak installed)

See DataTrak Operation

page 34.

Runaway Monitor ,

Runaway solenoid actuated. (if DataTrak installed) Enable runaway protection, if disabled, then see

Runaway, page 34, to reset the runaway solenoid.

3A2012S 39

Troubleshooting

Output low on both strokes.

Problem

Pump output low on only one stroke.

No output.

Pump operates erratically.

Erratic accelerated speed.

Runs sluggishly.

Cycles or fails to hold pressure at stall.

Air bubbles in fluid.

Loose suction line.

Poor finish or irregular spray pattern.

Difficulty priming

Cause

Air line restricted or air supply inadequate. Valves closed or clogged.

Fluid hose/gun obstructed.

Air motor icing.

Exhausted fluid supply.

Worn piston packings.

Open or worn intake valve.

Held open or worn ball check valves.

Worn piston packings.

Improperly installed ball check valves.

Exhausted fluid supply.

Held open or worn ball check valves.

Worn piston packing.

Suction tube too restrictive, causing pump to cavitate.

Fluid supply exhausted, clogged suction.

High viscosity fluid.

Open or worn piston valve or seal.

Open or worn intake valve.

Possible icing.

Filler material clumping causing extra friction on rods and seals.

Worn check valves or seals.

Solution

Clear air line; increase air supply. Check that valves are open.

Clear hose or gun*.

See air motor manual for instructions.

Refill and prime pump.

Replace.

Clear or service intake valve.

Check and repair.

Replace.

Check and repair.

Refill and reprime pump.

Check and repair.

Replace.

Use larger diameter tube

Refill supply and prime pump. Clean suction tube.

Reduce viscosity; increase fluid temperature, reduce flow rate by using smaller tip.

Clear piston valve; replace seal.

Clear or service intake valve.

See air motor manual for instructions.

Flush pump and replace packings.

Service lower. See lower manual for instructions.

Incorrect fluid pressure at gun.

Fluid is too thin or too thick.

Dirty, worn, or damaged spray gun.

Inlet ball stuck to seat

Suction hose/strainer too restrictive or clogged

Tighten. Use compatible liquid thread sealant or

PTFE tape on connections.

See gun manual; read fluid manufacturer’s recommendations.

Adjust fluid viscosity; read fluid manufacturer’s recommendations.

Service spray gun. See spray gun manual.

Tap pump with hammer to dislodge.

Remove inlet ball, flush dried material, re-install inlet ball.

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. Dis-

connect 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.

40 3A2012S

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.

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).

A B

C

Disconnect the Displacement

Pump

See manual 3A2313 for displacement pump service and parts information.

1. Flush the pump, see page 30.

2. Stop the pump in the middle of the stroke.

3. Relieve the pressure, see page 24.

4. Disconnect the air supply and fluid hoses.

ti12812a

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.

Threads are very sharp. Use a rag to protect hands when hand turning or carrying the pump.

ti12813a ti12816a

10. See displacement pump manual 3A2313 for pump service procedures and parts information.

3A2012S 41

Repair

Reconnect the Displacement

Pump

1. Disconnect air supply from air motor.

2. Hand-turn the displacement pump into the adapter plate.

3. Install coupler spring guard and TSL reservoir.

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.

8. Align fluid outlet as shown and tighten the jam nut.

9. Align the TSL reservoir (C) and push it down into place.

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).

11. Reconnect air supply to motor.

Cylinder, not wet cup, should be flush with plate. ti12814a

F IG . 35. Align cylinder and adapter plate.

D

42 3A2012S

Repair

3A2012S 43

Repair

Disconnect the Air Motor

See manual 3A2315 for air motor service and parts

information. See F IG . 36 on page 45.

1. Relieve the pressure, see page 24.

2. Disconnect main air supply line from the inlet on the air control panel (AE).

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. 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).

8. Lift up on the air motor to remove it. The tie rods (AJ) will remain attached to the air motor.

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

See F IG . 36 on page 45.

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).

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

A B

C ti12812a ti12813a

6. Use a 23 mm socket to remove the tie rod nuts (AF).

7. Use a 13 mm socket to loosen the top two screws (AG) that secure air motor to mounting bracket (AH).

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

8. Attached grounding wire to true earth ground.

44 3A2012S

Repair

AA

AC

AH

AJ

F IG . 36

3A2012S

AE

AD

AF

AB ti18456c

AG

AK

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 41,

Disconnect the Air

Motor on page 44, displacement pump manual 3A2313

or 312792, 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 F IG . 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 3A2012S

Repair

Repair Catalyst Pump

See F IG . 37 on page 49 for reference numbers.

Remove Catalyst Pump from System

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

6. Pull pivot knob (929) out to fully extend the slave pump rod (910).

7. Remove quick release pin (908) from slave pump housing (901).

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.

9. Place the slave pump housing (901) in a vise. Use the flats provided by the quick-release pin (908) hole.

10. Use a crescent wrench on the flats of the cartridge (902) to loosen then remove the cartridge and piston rod (910) assembly.

Repair Throat and Piston Seals

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.

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.

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).

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).

20. Install o-ring (902g).

21. Install snap-on seal (902e).

22. Lubricate the piston rod.

23. With bullet tool 16D007 installed on the piston rod, install cartridge assembly (902) onto the rod.

24. Remove the bullet tool.

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.

26. Remove seal (915) and guide (916) from transfer housing.

27. Remove spring (911), valve (912), and o-ring (913) from transfer housing.

28. Remove o-ring (913) from the valve (912).

29. Install new o-ring (913) on new valve (912).

13. Remove snap-on seal retainer (902e) then remove seal (902f).

3A2012S 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.

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.

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).

48 3A2012S

Repair

5

929

1

6

907

1

946

1

935

6

909

927

11

928

5

910

2

926

12

12 8

902

1 4

901

932

1

947

1

903

1 5

903a

3

6

909

6

908

919

920

911

912

913

914

8

915

916

917

7

8

903c

903b

918

9 10

920

919

925

923 5

921

Internal Mix shown

945

930

1

940

1

922

11

924

External Mix Only

947

1

932

1

939

924

11

946 ti21344a1

1

938

939

F IG . 37: Catalyst Pump Details

947

1

937

1

934

1

1

3

3A2012S ti19060a

902d

902b

13

902f

902a

902g

902f

902e

14

1

2

Apply pipe sealant to threads.

4

Apply thread locker to mating surfaces or threads.

3

Apply grease to mating surfaces or threads.

Torque to 240 in-lb (27.1 N•m).

5

Torque to 225-275 in-lb (25.4-31.1 N•m).

6

Loop large end of lanyard over gauge prior to assembling gauge. Attach small end of lanyard to split ring on pin.

7

Note orientation of u-cup.

8

9

Torque to 30-50 in-lb (3.4-5.6 N•m).

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.

49

System Parts

System Parts

Systems

121

152

4 107

5

4

106

111

110

105

1

109

108

7

108

113

8 104

113

103

104 8

102

114,115,116

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).

122

50 ti19056b

3A2012S

System Parts

Systems

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.

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 Description

16N918 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

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

2 2

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 1 1 1 1 1 1

3 3 3 3 3 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

 Item not shown.

 Replacement Danger and Warning labels, tags and cards are available at no cost.

3A2012S 51

System Parts

Ref.

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

118

119

121

122

123

Part Description

16N918 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

124 

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

125 

126 

258853 GUN, internal, gel

16M736 SUPPLY HOSE, 55 gallon

16M810 KIT, FRP

151   16D136 LABEL, warnings

152 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 6 6 6 6 6 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 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 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

3 3 3 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

3 3 3 3 3 3 3 3 3 3 3 3 3 3 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 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 3A2012S

System Parts

Ref.

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

118

119

121

122

123

Part Description

16N918 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

1 1 1 1

1 1 1

1 1 1 1

1 1 1 1 1 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 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 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1

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 3 3 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

3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1

1

1 1

124 

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

1

16M583 HOSE, bundle, 50 ft chop 1

258970 GUN, external mix, chop, with cutter 1 1 1

258840 GUN, external mix, gel

258971 GUN, internal mix, chop, with cutter

125 

126 

258853 GUN, internal, gel

16M736 SUPPLY HOSE, 55 gallon

16M810 KIT, FRP

151   16D136 LABEL, warnings

152 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 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 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.

3A2012S 53

System Parts

Ref.

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

118

119

121

122

123

Part Description

16N918 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

124 

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

125 

126 

258853 GUN, internal, gel

16M736 SUPPLY HOSE, 55 gallon

16M810 KIT, FRP

151   16D136 LABEL, warnings

152 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

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

2 2 2 2 2 2 2 2 2 2 2

3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

3 3 3 3 3 3 3 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

 Item not shown.

 Replacement Danger and Warning labels, tags and cards are available at no cost.

54 3A2012S

System Parts

Ref.

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

118

119

121

122

123

Part Description

16N918

---

---

W13DFC

W17CFS

U82037 PUMP, FRP, 9:1

111799

16P125

119999

24M092

16N741

16N740

120476

111040

16M564

16M565

U60648 Label, ratio, 9:1, FRP

16N761

16U750

113093

114109

121141

16D939

114109

121141

---

238909

---

124071

16M588

16M587

124 

16M586

16M591

16M590

16M589

16M585

16M584

16M583

258970

258840

258971

258853

24P435 GUN, internal mix, chop with cutter, HI FLOW

125 

126 

16M736

16M810

151   16D136

152 24M692

1

1

1

1

1

1

1

1

1

1

1

1

1 1 1

1 1 1

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 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 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 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 3 3 3 3 3 3 3 3 3 3 3 3 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

3 3 3 3 3 3 3 3 3 3 3 3 3 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 1 1 1

3A2012S 55

System Parts

Carts

205

203

201

202

204

208 1

211

207 1

209

210

1

Apply sealant to threads.

Ref Part Description

201

202

203

204

205

---

---

16P425

100023

110837

111040

CART, chop

CART, pole

RESERVOIR, gravity feed, 2.5 gallon

WASHER, flat

SCREW, flange, hex

NUT, lock, insert, nylock, 5/16

207  16V707 BUSHING, filter, tank

208  20170-00 FITTING, 3/8 tube x 1/4 npt; sst; elbow

209

210

---

---

211  16V733

TUBE, polyethylene, 0.375 OD

TUBE, polyethylene, 0.250 OD

FILTER, tip (3-pack)

221

222

223

224

16M465 CASTER, locking (not shown)

113962 WASHER (not shown)

100321

122051

NUT (not shown)

CASTER, non-locking (not shown)

 Included in Catalyst Outlet Kit 16N854.

1

1

1.25

5

1

2

4

4

1

4

Cart, for use with boom

1

Quantity

Cart, not for use with boom

1.25

5

1

4

4

4

1

1

4

4

1

1

4

2

56 3A2012S

System Parts

3A2012S 57

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

304

303

Pole not included

Ref Part Description

301 16M666 BRACKET, pump, pole mount

302 16M466 BRACKET, catalyst tank

303  --CLAMP, pipe, set

304  ---

305  ---

306  ---

307  ---

PLATE, cover, clamp

SCREW, cap, hex head

WASHER, hardened, sae

NUT

308  --WASHER, lock, spring

309 110837 SCREW, flange, hex

310 100023 WASHER, flat

311 111040 NUT, hex

312 111799 SCREW, cap, hex head

Qty

1

1

4

8

8

4

8

4

4

8

4

4

 Included in pipe clamp kit 16P291.

ti18528c

58 3A2012S

System Parts

Boom, 16N761

ti19076a

401

413

407

411

412 410

408

412

409

401

414

406 405

404

403

1

2

Item shown for reference only.

2 in. ID schedule 40 pipe not included.

NOTE: Use rubber straps to secure gun hoses to boom.

Ref Part

401 ---

Description

SUPPORT, boom, mast

402  114271 STRAP, retaining

403 16M626 COVER, roving, guides

404 22486-00 GUIDE, roving, ceramic

405 100016 WASHER, lock

406 100015 NUT, hex mscr

407 100103 PIN, cotter

408 16M811 CHAIN, spring, boom

409 112248 NUT, hex

410 105170 SCREW, cap hex head

411 444 SPRING, boom

412 555626 WASHER, 1/4 plain flat big

413 16M808 PIN, clevis with cotter pin

414 16N950 EXTENSION, boom

 Not shown.

--- Not for sale.

1

1

1

1

2

1

1

Qty

1

10

5

12

12

12

1

3A2012S 59

System Parts

Air Panel

510

533

505

510

541 504

517 503

537 542

531

501

509

522

1

512

525

506 529

502

522

509

511

520

541

538

521

515

522

539

540

514

519 ti19058b

527

504

509

1

Plug supplied with regulator (504).

2

Apply sealant to all non-swiveling pipe threads.

Ref Part

501 ---

Description

PANEL, air control

502 15T536 REGULATOR, air, 3/8 npt

503 15T538 NUT, regulator

504 116513 REGULATOR, air

505 116514 NUT, regulator

506 15T500 GAUGE, pressure, air, 1/8

509 15T866 FITTING, elbow, swivel, 1/8 npt x 5/32 t

510 15T498 FITTING, 90°, swivel, 5/32t x

1/8fnpt

511 15T937 FITTING, elbow, male, 1/4

3

1

512 --npt(m) x 5/32 OD tube

VALVE, ball, 1/2 npt x 1/2 npt 1

514 --FITTING, straight, 1/2 x 3/8 tube 1

515 121212 FITTING, elbow, swivel, 1/2 t x 2

3/8 npt(m)

517 16U556 LABEL, air control panel, FRP

519 124071 PLUG, fitting, push-to-connect

520 --TUBING, air, 3/8 in. OD; polyurethane

Qty

1

1

1

3

2

2

2

1

1

0.18

Ref Part

521 ---

Description Qty

TUBE, polyethylene; 1/2 in. OD 0.68

522 --TUBE, nylon, round, black

525 114381 SCREW, cap, button head

527 124496 VALVE, air check

529 --BRACKET, air control

531 113498 VALVE, safety, 110 psi

533 ---

537 96/0005-

INSERT, control panel

WASHER, lock, ext, #10, ms

1.37

3

1

1

1

1

2

538

2/99

16U452 FITTING, elbow, 1/4npt(m) x 1

539

540

541

542

1/2 tube

16U479 FITTING, cross, 1/2 tube, plastic

16U480 FITTING, 1/2 stem x 1/2npt(m), plastic

16U481 FITTING, tee, 1/4 npt(m), 3/8 t,

1/4 npt(f)

105332 NUT, lock

1

1

2

2

60 3A2012S

Slave Pump Linkage, 16P125

2001a

2001d

2001f

2005

2006

2007

2004

2002

2003 ti19057a

Ref Part

2001 ---

Description

HARNESS, slave linkage

2001a 16N776 KIT, upper link, slave

2001b 16N775 KIT, lower link, slave

2001c 119999 BOLT, shoulder

2001d 116969 NUT, lock

2001e 7486-05 WASHER, flat, standard, #10

2001f 7486-03 WASHER, flat, fender, 1/4

2002 16M362 LINK, fixed, pivot

2003 116596 SCREW, cap, hex head

2004 119999 BOLT, shoulder

2005 16N774 LINK, yoke, upper, assy

2006 24M092 PIN, quick release, 1.5 x 0.25

2007 111040 NUT, lock, insert, nylock, 5/16

2008 120476 BOLT, shoulder, 5/16

Ratio Indicator labels (111), 75cc (16M565) and

100cc (16M564), are not included. Purchase separately.

Qty

1

1

1

1

1

1

2

1

1

1

1

1

1

1

3A2012S

2008

2001e

2001c

System Parts

2001b

61

System Parts

Resin Pumplines

615

613

609 5

617 7

614

601

616

606

1 602

6 607

608

603

2 605

7 620

7 619

612

610

611 4

3

618

604 3

622 7

621 7

1

Torque to 50-55 ft-lb

(68-75 N•m).

2

3

Torque to 50-60 ft-lb (68-101 N•m).

Assemble pump (604) to top of pump adapter (603), 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).

4

Torque to 250 in-lb (28.2 N•m)

5

Torque to 70-75 ft-lb (95-102 N•m).

6

Torque to 75-80 ft-lb (102-108 N•m).

7

Apply thread sealant.

62 3A2012S

Ref Part Description

601 M07LNL MOTOR, double ended, 4.5 in.

602* 15M662 ROD, tie

603* 16U435 ADAPTER, displacement pump

16U426 ADAPTER, displacement pump

16U428 ADAPTER, displacement pump

604 LW100C PUMP, 100 cc

LW075S PUMP, 75 cc

LW150A PUMP, 150 cc

605* 15U606 NUT, lock, M16 x 2

606*† 24A619 COLLAR, coupling (10 pack)

607* 15T311 NUT, coupler

608* 24A625 RESERVOIR, TSL, 75cc lower

(includes 618)

24A626 RESERVOIR, TSL, 100cc lower

(includes 618)

24A628 RESERVOIR, TSL, 150 cc lower

(includes 618)

609 16N774 LINK, yoke, upper

610 16M362 LINK, fixed, pivot

611 116596 SCREW, cap, hex head

612 24F620 FILTER, fluid, 5000 psi, 100 mesh

U82200 FILTER, fluid, 5000 psi, 60 mesh

613 24D642 MUFFLER

614 100361 PLUG, pipe

615 16M355 FITTING, adapter, muffler, 1/2 npt x 1 in. - 14

616* 16M477 SPRING, guard

617 15V204 FITTING, elbow, 1/2 npt x 1/2 tube

618*† --O-RING, wetcup

619 161490 ADAPTER, nipple

620 162485 COUPLER, reducing

621 123075 FITTING, elvow, 1” nps x 1” npt

622 100474 COUPLING

3

Quantity

W13DFC, 13:1 W17CFS, 17:1 U82037, 9:1

1 1 1

3

1

3

1

1

1

1

3

2

1

3

2

1

1

2

1

1

3

1

1

1

2

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

* Included in Connecting Kit. See page 64 to order the

correct kit for your pump.

† See

Resin Pumpline Kits on page 64.

System Parts

3A2012S 63

System Parts

Resin Pumpline Kits

Kit Description

Wet-Cup O-Ring (618)

Package of 10

Coupling Collars (606)

Package of 10

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 or 312792. For air motor repair kits , see manual 3A2315.

LW075S

24A631

24A619

16N242

LW100C

24A632

24A619

LW150A

24P196

24A619

16N243 17E099

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.

64 3A2012S

Resin Filter

24F620 or U82200

720

704

705

703

706

702

721

708

719

3

4

5

6

Press fit spring (710) to bottom of filter bowl (701).

Apply thread lubricant.

Apply grease.

Apply thread sealant to all non-swiveling pipe threads.

Ref Part Description

701 24C501 BOWL, filter

702 171942 HEAD, filter

703 238635 VALVE, ball, carbon steel

704 205447 COUPLING, hose

705 --HOSE, nylon, 225 psi

706 100509 PLUG, pipe

707 104361 PACKING, o-ring

708 186075 SUPPORT, filter

710 171941 SPRING, compression

711 100040 PLUG, pipe

717  172479 TAG, warning (not shown)

718 GC2069 FITTING, swivel, 3/8 nptm x

719 *

3/8 npsm

STRAINER, 100 mesh screen

720 155541 FITTING, swivel, elbow

721 155655 UNION, adapter

1

1

1

 Replacement Danger and Warning labels, tags and cards are available at no cost.

1

1

1

1

1

Qty

1

1

1

1

1

1

7

* Strainer Options:

Mesh 2-pack

30 224458

25-pack

238436

60 224459 238438

100 224468 238440

710 3

707 5

4

701

200 ti19059a

711

224469 238442

3A2012S

System Parts

65

System Parts

Resin Supply Hose

16M736

807

801

802

Ref

801

802

Part Description

220372 HOSE, coupled, 6 ft

197682 TUBE, suction

803

804

114967 COUPLING, pipe, 1 in.

195151 TUBE, intake

805* 20397-01 FILTER, 24 mesh, 1 in. npt

807 16M776 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)

803

804

805

1

Apply pipe sealant to all non-swiveling pipe threads.

66 3A2012S

.

System Parts

3A2012S 67

System Parts

Catalyst Slave Pumps

926

12

910

2 12 8

902

1 4

901

932

1

947

1

1

6

907

1

946

1

935

6

909

903

1 5

903a

3

6

909

6

908

919

920

911

912

913

914

8

915

916

7

917

8

903c

903b

3

919

5

925

923

921

Internal Mix shown

918

9 10

920

Series D only

1 15

936

Series D only

940

1

945

1

922

WLE

11

924

External Mix Only

947 1

932 1

939

924

11

930

1

946 1

940

1 ti19060a

902d

902b

13

902f

902a

902g

902f

902e

14

1 Apply pipe sealant to threads.

2 Apply thread locker to mating surfaces or threads.

3 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).

6

Loop large end of lanyard over gauge prior to assembling gauge. Attach small end of lanyard to split ring on pin.

7 Note orientation of u-cup.

8 Torque to 30-50 in-lb (3.4-5.6 N•m).

9

10

Clean cylinder inner diameter with soft cloth or equivalent, prior to assembly.

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).

938

939

947 1

937 1

934 1

68 3A2012S

System Parts

Qty.

Catalyst Pumps

Qty.

Ref.

Part

901 ---

902 24C479

902a ---

902b † ---

902d † ---

902e  16P186

902f  16A981

902g  123556

903 16N975

903a 224807

903b 15C780

903c 15C972

907 113641

124432

908 123595

909 124193

910 16N964

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)

BASE, valve

HANDLE

PIN, spring

GAUGE, pressure, fluid

GAUGE, 160 psi

PIN, quick release

CABLE, lanyard, 5 inch

ROD, piston, slave pump (also includes 919, 920, and tool

16D007)

SPRING, transfer housing

VALVE, poppet

1 1

1 1

1 1

1 1

1 1

1 1

2 2

1 1

1 1

911  123636

912  16K928

913  123934

914 16K960

915  LPA-126

916  LPA-127

O-RING, 003, FKM

HOUSING, transfer, etched

SEAL, radial

GUIDE, piston

1 1

1 1

1 1

1 1

1 1

1 1

917 16A666

918 16N965

CAP, transfer housing

CYLINDER, slave pump (also includes 919 [Qty 2] and 920

[Qty 2])

1

1

1

1

O-RING, o-ring, silicone, 2-014 2 2 919  ‡ CJ-143

920  ‡ 124061

921 LPA-144

922 16N976

923 ‡ ---

RING, backup, 0.518 ID,

0.053 wide

NUT, lock

HOUSING, inlet, slave

SEAT, ball, 7/16 dia.

924 --BEARING, flanged, 0.375 ID

925 LPA-134-02 BALL, spherical

2 2

1 1

1 1

1 1

2 2

1 1

926 16N617

930 114339

932 123628

934 297085

KIT, repair, catalyst pump yoke 1 1

FITTING, union, swivel, 1/4 npt 1 1

FITTING, adapter, 1/8 npt - #4 jic

FITTING, elbow, 0.125 in., st

1 1

1

1 1

1 1

1 1

1

1

1 1

1 1

1 1

Ref.

Part

935

936

110208

Description

PLUG, pipe, headless

94/0320-1/98 FITTING, nipple, 1/4; series D only

937 124379

938

939

940

16V706

---

24U857

080803

VALVE, check, npte x npti, 100 psi

FITTING, tee, compression, 1/4

TUBE, polyethylene

VALVE, ball, mini; not used on series D

VALVE, ball, 1/4 npt, ff, 316 sst; series D only

945

946

947

16V703

16V704

16V705

1

1

1

1

1

1

1

0.5

1

1

FITTING, 1/4 npt x 3/8 tube, sst 1 1

FITTING, 1/8 npt x 1/4 tube, 90, sst

1 1

FITTING, 1/8 npt x 1/4 tube, sst 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.

 Parts available in piston valve repair kit 16N962.

 Parts and tools available in throat seal repair kit

16N963.

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

3A2012S 69

System Parts

Catalyst Reservoir

16P425

1 1011

1012

Ref Part

1001 ---

Description

TANK, gravity feed, 2.5 gallon

1002 24M159 STRAINER, tank, gravity feed

1010 16M754 LABEL, maximum fill line

1011 16V704 FITTING, 1/8 npt x 1/4 tube, 90; sst

1012 16M738 LABEL, hazardous material diamond

Qty

1

1

1

2

1

1001

1002

1

2

Apply pipe sealant to threads.

Apply sticker so that the level line is even with the 2.5 gallon mark on tank (1001).

1010 2

1001

For outlet strainer and filter, see

Carts on page 56.

70 3A2012S

System Parts

Hose Bundles

1102

1104

1109

1105

1114

3A2012S

1115

1101

1108

1106

1111

1103

1113

1104 (Internal Solvent/

External AAC)

1107

1102 (Catalyst)

1105 (External Atomizing Air/

Internal Chop AAC Air)

1101 (Chopper

Air/Internal Gel AAC)

1103 (Resin) ti21345a1

71

System Parts

72 3A2012S

System Parts

Hose Bundles

Ref Part Description

1101* 16J767 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

16M583,

16M584, 16M585,

50 ft 50 ft 16M586,

16M587, 16M588,

25 ft, 25 ft, 16M589,

16M590, 16M591,

35 ft, 35 ft,

50 ft, chop internal gel external gel

25 ft, chop internal gel external gel

35 ft, chop internal gel external gel

1

53 ft

1

1

1

53 ft

1

1

1

1

1

1

2.5 ft

1

1

1

1

1

1

1

1

1

1

1

1

53 ft

1

1

1

1

28 ft

1

1

1

28 ft

2

1

1

1

1

1

1

2.5 ft

1

1

1

1

2

1

1

1

1

1

1

1

28 ft

2

1

1

1

1

35 ft

1

1

1

38 ft

1

1

1

1

1

1

1

1

2.5 ft

1

1

1

1

1

1

1

1

1

1

1

1

1

1

38 ft

1

1

1

1

1

1

 Replacement Danger and Warning labels, tags and cards are available at no cost.

† 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.

* Series C and prior chop hoses use 16J769. Series D or later chop hoses are shown in the table.

 Not shown.

3A2012S 73

System Parts

Accessory Parts

Heater Kits

1202f 1202e

1202d

16N014 and 16N015 Kits

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

1206

1205

1204

Reducing pipe nipple (1209) can be used instead of elbow fitting (1214).

1201

1202d

1202c

1202b

1202a

1215 1210 1210 1213

74

1202b

1202a

1202f 1202e

1202d

1

1

2

1214

1213

1210

16N0169, 16N017, 16N018, and 16N019 Kits

1202a

1203

1204

1202d

1202c

1215

1211

1204

1203 ti21346a

1213 1

1214

1

1208

1210

1213

1211 ti21347a

3A2012S

System Parts

Heater Kits

Ref Part Description

1201* 16N013 BRACKET, heater

1202* 16P291 KIT, pipe clamp

1202a † 19891-00 CLAMP, pipe, set

1202b † 19892-00 PLATE, cover, clamp

1202c † 115211 SCREW, cap, hex hd

1202d † 113962 WASHER, hardened

1202e † 100018 WASHER, lock, spring

1202f † 100321 NUT

1203* 100058 SCREW, cap, hex head

1204* 110755 WASHER, plain

1205* 100131 WASHER, lock

1206* 100015 NUT, hex, mscr

1208* 162449 NIPPLE, reducing

1209* 159239 NIPPLE, pipe, reducing

1210* 158491 NIPPLE

1211* H55003 HOSE, coupled, 5600 psi

1212* --TAPE, PTFE

1213* 155470 SWIVEL, union, 90°; 1/2 x 1/2 npt

1214* 217430 SWIVEL, union, 90°; 1/2 x 3/8 npt

1215 245848 HEATER, viscon HP

245863 HEATER, viscon HP

245867 HEATER, viscon HP

245869 HEATER, viscon HP

226819 HEATER, viscon, 240 volt

226816 HEATER, viscon, 120 volt

1

1

4

4

2

1

4

8

2

2

16N014,

120v, FM

1

2

2

4

1

1

1

2

1

1

1

1

4

4

2

1

4

8

2

2

16N015,

240v, FM

1

2

2

4

1

1

1

1

4

4

2

1

4

8

2

2

Quantity

16N016,

120v, hazardous

16N017,

240v, hazardous

1

2

1

2

2

4

1

1

1

1

2

4

1

1

4

4

2

1

4

8

2

2

1

2

1

1

1

2

1

1

1

2

1

1

1

1

4

4

2

1

4

8

2

2

16N018,

120v, non- hazardous

1

2

2

4

1

1

1

1

4

4

2

1

4

8

2

2

16N019,

240v, non- hazardous

1

2

2

4

1

1

1

2

1

1

1

2

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.

3A2012S 75

System Parts

Solvent Pressure Pot Kits

ASME Pressure Pots, 2-gallon 16M893 and 5-gallon 16M894

2 1307 1311

1306

3

2 1310

2 1309

2 1303

1304 2

1305 2

1302 2

1301 1

1

2

3

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.

Apply pipe sealant.

Clamp ground cable (1311) to handle on tank (1101). Ground cable not shown.

Ref Part Description

1301 20324-00 TANK, solvent, 2 gallon

(assembly 16M893 only)

20324-01 TANK, solvent, 5 gallon

1302 16D939

(assembly 16M894 only)

FITTING, nipple, reducing

1303 11021-23 PLUG, pipe, 1/4

1304 18470-05 VALVE, ball, 2-way, 1/4nptf

1305 RM-856-04 FITTING, elbow, 1/4 nptm x

1/4 nptm

1306 20655-04 FITTING, elbow, 3/8 nptm x

1307 103347

3/8 tube

VALVE, safety, 100 psi

1308 21035-00 STRAINER, pick-up, material

1309 21462-01 FITTING, adapter, 1/4 nptm x

1310 3165

3/8 nptf

VALVE, ball, 2-way,

3/8 female, 3/8 male

1311 17440-00 CLAMP, grounding

1312  13867-68 TANK LID GASKET

 Item not shown.

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

76 3A2012S

ASME and CE-Approved Pressure Pots, 16M874 and 16M875

1 1411

1 1406

1 1410

1 1408

1 1412

1

2

3

Apply pipe sealant.

Clamp ground cable (1423) to handle on tank (1401). Ground cable not shown.

Must be installed on the outlet side. The outlet is the port without the cross hole.

1401

1404

1401

1414

1401

1403

1402

1408 1

1409 1

1406

1405 3

System Parts

1

Ref Part Description

1401 236086 TANK, pressure assy, 2 gal.

(assembly 16M874 only)

236087 TANK, pressure assy, 5 gal.

(assembly 16M875 only)

1402 165053 PACKING, o-ring

1403 188880 PLUG, lid

1404 188784 NUT, jam, hex

1405 171976 TUBE

(assembly 16M875 only)

185531 TUBE, siphon (assembly

1406 ---

16M874 only)

BUSHING, hex, 3/8npt x 1/4npt, male/female

1407 111763 FITTING, elbow, 1/4 npt

1408 18470-05 VALVE, ball, 2-way, 1/4nptf

1409 --FITTING, nipple, reducing

1410 108673 TEE, street

1411 103347 VALVE, safety, 100 psi

1412 --FITTING, connector, male,

3/8 npt

1413 210575 CAP, filler (assembly 16M875 only, not shown)

1414 176347 LABEL, identification

Qty

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

2

3A2012S

Ref Part Description

1415 --LABEL, designation

1416  175078 LABEL, warning

1421 308370 MANUAL

1423 17440-00 CLAMP, grounding

1424 171988 O-RING (for filler cap, item 1413, not shown)

 Replacement Danger and Warning labels, tags and cards are available at no cost.

Qty

1

1

1

1

1

77

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 Description

1501 16M559 PUMP, solvent, FRP, flush

1502 16M652 TANK, solvent, 2.5 gal assembly

(assembly 16M560 only)

16M651 TANK, solvent, 5 gal assembly

(assembly 16M561 only)

1503 16M769 KIT, pump fasteners

1504 --TUBING, nylon, round

1505 16N891 KIT, pick-up tube, 2.5 gallon

(16M560 only)

16N892 KIT, pick-up tube, 5 gallon

(16M561 only)

1

3

1

1

Qty

1

1

1

78 3A2012S

DataTrak Upgrade Kit

16M881

1602

1602

Ref Part Description

1601 * 24A354 SMART AIR VALVE (not shown)

1602 24A576 DATATRAK CONVERSION KIT

* See FRP air motor manual.

Qty

1

1

System Parts

3A2012S 79

System Parts

Carts for 55 Gallon Barrel,

16M896

1717

1706

1704

1718

1705

1716

1711

1714

1715

1713

1703

1708

1709

1710

1702

Ref Part

1701 ---

Description

PLATE, 55 gal drum

1702 16P134 CASTER, rigid

1703 16M465 CASTER, locking

1704 113962 WASHER, hardened, sae

1705 100321 NUT

1706 16N977 BRACKET, drum cart

1707 100521 SCREW, cap hex head

1708 100023 WASHER, flat

1709 104008 WASHER, lock, spring

1710 GC2096 NUT, hex, standard, 5/16-18

1711 16N978 BRACKET, handle, drum cart

1712 100424 SCREW, cap, hex head

1713 116645 SCREW, cap, hex head

1714 100696 WASHER, wrought

1715 100052 WASHER, lock

1716 124291 PIN, spring

1717 258982 HANDLE, cart

1718 100018 WASHER, lock, spring

--- Not for sale.

2

1

8

1

16

8

2

8

1

1

1

1

4

Qty

1

2

2

6

4

80

1712

1704, 1705, 1718

1701

WLE

1707

1708

3A2012S

Roving Box Bracket

16M961

1802

1801

1803

1804,1805

1806 ti18525b

NOTE: Second roving box shown for reference only to illustrate installation.

1807†

Ref Part Description

1801 16M619 BRACKET, roving

1802 16M622 BRACE, roving box

1803 122741 SCREW, hex cap, 1/4 x 0.50

1804 104123 WASHER, lock, spring

1805 112248 NUT, hex

1806 16M965 CLAMP, u-bolt

1807† 15J889 SCREW, hex

† Long bolts are only used if two kits will be installed side by side.

Qty

1

1

2

2

2

2

2

System Parts

3A2012S 81

System Parts

Extension Hoses

Gel Hose

1907

Chop Hose

1903

1913

1906

1906

1904

1902

1904

1905

1901

1905

1907

1903, 1907 (Resin)

1903 1913

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)

1902 ti21348a

Ref Part Description

1901 16J766 TUBE, 3/8 in. polyethylene, 25 ft

590570 TUBE, 1/2 in. polyethylene

1902 24J730 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.

25.5 ft

1

1

1

25 ft

1

1

1

1

1

1

1

1

Quantity

16M718, for internal gel

1

1

1

1

1

1

1

1

1

16M719, for external gel

1

1

1

25 ft

1

1

1

1

1

* Series C and prior chop hoses use 123554. Series D or later chop hoses are shown in the table.

82 3A2012S

Dimensions

Dimensions

Cart and Boom

B

ti18526b

C

A

¡

F

Top View

¡

E

Ref.

Description

A

(Max Width)

144 in.

(3658 mm)

B

(Max Height)

100 in.

(2540 mm)

C

(Max Depth)

192 in.

(4877 mm)

E

(Radius)

144 in.

(3658 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).

F

(Radius)

72 in.

(1828 mm)

3A2012S 83

Dimensions

Cart Only

B

A

Wall/Pole Mount

B

A

C

ti18524d

Ref.

A

(Max Width)

B

(Max Height)

C

(Max Depth)

Cart Only

29.5 in.

(749 mm)

47.75 in.

(1213 mm)

32.5 in.

(826 mm)

C

ti18496b

Ref.

A

(Max Width)

B

(Max Height)

C

(Max Depth)

Wall/Pole Mount

39.0 in.

(991 mm)

46.6 in.

(1183 mm)

32 in.

(813 mm)

84 3A2012S

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 . . . . . . . . . . . . . . . . . . . . . . . . 9:1 Systems: 900 psi (6.2 MPa, 62 bar)

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 86

Catalyst wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See

Catalyst Pump Technical Data , page 86

* Maximum fluid temperature rating determined by lowest rated component in system.

3A2012S 85

Technical Data

Pumpline Technical Data

Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . .

9:1 Systems: 900 psi (6.2 MPa, 62 bar)

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9:1 Systems: 1.8 gpm (free flow at 70 cpm)

Maximum fluid temperature

13:1 Systems: 1.5 gpm (free flow at 70 cpm)

17:1 Systems: 1.1 gpm (free flow at 70 cpm)

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. . . . . . . . . . . . . . . . . . . . . . . 2000 psi (14.0 MPa,140 bar)

External catalyst pump version . . . . . . . . . . . . . . . . . . . . . . 90 psi (0.63 MPa, 6.3 bar)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 lb (1.6 kg)

Wetted parts**. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psi (21.0 MPa, 210 bar); PTFE

1/2 in. resin hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (28.0 MPa, 280 bar); nylon

3/8 in. resin hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 psi (23.1 MPa, 231 bar); nylon

Solvent/AAC air hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 psi (1.6 MPa, 16 bar); nylon

3/8 in. OD air hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 psi (0.9 MPa, 9 bar); PET

1/4 in. OD atomizing/AAC air hose . . . . . . . . . . . . . . . . . . . 125 psi (0.9 MPa, 9 bar); PET

1/2 in. OD air hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.

86 3A2012S

Technical Data

3A2012S 87

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

Sealant and Adhesive Dispensing Equipment

For the latest information about Graco products, visit www.graco.com

.

For patent information, see www.graco.com/patents

.

TO PLACE AN ORDER, contact your Graco distributor, go to www.graco.com, or call to identify the nearest distributor.

If calling from the USA: 1-800-746-1334

If calling from outside the USA: 0-1-330-966-3000

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.

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

Revision S, September 2019

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