Graco ti18496b, ti18526c, ti18524d User Manual

Instructions - Parts

3A2012J

FRP Proportioner

Low emission internal/external mix gel coat and chop proportioners. For use with resin and catalyst in hazardous and non-hazardous locations. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual and all component manuals. Save all instructions.

See page 4 for model and agency approvals information. See page 83 for maximum working pressure and other specifications. For patent information, see www.graco.com/patents.

WARNING

FIRE AND EXPLOSION HAZARD

Oil left in the system at the factory can react with catalyst and create a fire or explosion.

• Flush before first use.

• Do not add catalyst to the catalyst reservoir until the system has been flushed.

ti18526c

ti18524d

Wall Mount SystemCart and Boom System

Cart System

ti18496b

II 2 Gc T5

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Important Methyl Ethyl Ketone Peroxide (MEKP)

Safety Information . . . . . . . . . . . . . . . . . . . . . . 8

Important Two-Component Material Information . 9

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 9

Keep Resin and Catalyst Components Separate 9

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Component Identification . . . . . . . . . . . . . . . . . . 11

Air Control Panel . . . . . . . . . . . . . . . . . . . . . . . . 12

Air Motor and Resin Displacement Pump . . . . . 13

Catalyst Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Solvent Flush Systems . . . . . . . . . . . . . . . . . . . 15

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Before Installation . . . . . . . . . . . . . . . . . . . . . . . 16

Location Requirements . . . . . . . . . . . . . . . . . . . 16

System Mounting (Wall Mount Systems Only) . 16

System Assembly . . . . . . . . . . . . . . . . . . . . . . . 18

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connect Fluid and Air Lines . . . . . . . . . . . . . . . 21

Flush Before First Use . . . . . . . . . . . . . . . . . . . 23

Fill Supply Tanks . . . . . . . . . . . . . . . . . . . . . . . . 23

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . 24

Pressure Relief Procedure and Shutdown . . . . 24

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

DataTrak Operation . . . . . . . . . . . . . . . . . . . . . 33

Replace DataTrak Battery or Fuse . . . . . . . . . . 38

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Catalyst Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Resin Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

General Information . . . . . . . . . . . . . . . . . . . . . . 42

Disconnect the Displacement Pump . . . . . . . . . 42

Reconnect the Displacement Pump . . . . . . . . . 43

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

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

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

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

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

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

Carts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Wall or Pole Mount Kit, 16N918 . . . . . . . . . . . . 57

Boom, 16N761 . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Air Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Slave Pump Linkage, 16P125 . . . . . . . . . . . . . . 60

Resin Pumplines . . . . . . . . . . . . . . . . . . . . . . . . 61

Air Motor and Pump for

Resin Pumpline . . . . . . . . . . . . . . . . . . . . . . 62

Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Resin Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Resin Supply Hose . . . . . . . . . . . . . . . . . . . . . . 64

Catalyst Slave Pumps . . . . . . . . . . . . . . . . . . . 66

Catalyst Reservoir . . . . . . . . . . . . . . . . . . . . . . . 68

Hose Bundles . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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

Accessory Parts . . . . . . . . . . . . . . . . . . . . . . . . . 72

Heater Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Solvent Pressure Pot Kits . . . . . . . . . . . . . . . . . 74

Solvent Diaphragm Pumps . . . . . . . . . . . . . . . . 76

DataTrak Upgrade Kit . . . . . . . . . . . . . . . . . . . . 77

Carts for 55 Gallon Barrel, 16M896 . . . . . . . . . 78

Roving Box Bracket . . . . . . . . . . . . . . . . . . . . . . 79

Extension Hoses . . . . . . . . . . . . . . . . . . . . . . . . 80

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Cart and Boom . . . . . . . . . . . . . . . . . . . . . . . . . 81

Cart Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Wall/Pole Mount . . . . . . . . . . . . . . . . . . . . . . . . 82

Pumpline Wall Mounting Bracket Dimensions . . 83

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 86

2 3A2012J

Related Manuals

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

Manual Description

™

3A0232 RS 3A2313 U-Cup Displacement Pump

3A2315 NXT 332451 FRP Stainless Steel Fitting Kit 308981 Air Operated Diaphragm Pumps 309524 Viscon HP Heater Instructions

307363 Viscon

313541 DataTrak

308370 307273 Fluid Outlet Filter 407019 Chop Cart Legs Kit

Gun Instructions-Parts

Air Motor for FRP

Heater Instructions

™

Conversion Kit Instructions

ASME and CE-Approved Pressure Pot Instructions (Solvent Flush Pressure Pot)

Agency Approvals

Manual Description

407020 55 Gallon Drum Kit 407021 Roving Box Bracket Kit 407022 Deluxe Inlet Seat Removal Tool 407023 5 Gallon Catalyst Reservoir Kit 407024 Boom Kit

407025 DataTrak 407026 Wall or Pole Mount Kit 407027 Linkage Replacement Kit 407028 Resin Pump Connecting Kit 407031 Diaphragm Pump Solvent Flush Kit

Non-CE Approved Solvent Pressure Pot

407032

407033 407042 Heater Kits

Kits ASME and CE-Approved Pressure Pot

Kits

™

Upgrade Kit

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

Base FRP System with no accessories*

Accessories

* Solvent pots do not affect Atex rating.

II 2 Gc T5

See accessory manuals listed in Related Manuals section for approvals.

3A2012J 3

Models

Internal or

Ratio

Internal Mix

13:1

Internal Mix

17:1

External

Mix

External

Mix

External

Mix

Gel or

Chop

Gel

Chop

Gel

Chop

Gel

No Cart Cart Cart, Mast, and Boom

Hose

Length

Part No.

16R065 25 (7.6) 16R002 25 (7.6) 16R053 25 (7.6)

16R068 35 (10.7) 16R044 35 (10.7) 16R056 35 (10.7)

16R071 50 (15.2) 16R047 50 (15.2) 16R059 50 (15.2)

16R074 --- 16R050 --- 16R062 ---

16R135 25 (7.6) 16R123 25 (7.6) 16R004 25 (7.6)

16R138 35 (10.7) 16R114 35 (10.7) 16R126 35 (10.7)

16R141 50 (15.2) 16R117 50 (15.2) 16R129 50 (15.2)

16R144 --- 16R120 --- 16R132 ---

16R030 25 (7.6) 16R001 25 (7.6) 16R018 25 (7.6)

16R033 35 (10.7) 16R009 35 (10.7) 16R021 35 (10.7)

16R036 50 (15.2) 16R012 50 (15.2) 16R024 50 (15.2)

16R039 --- 16R015 --- 16R027 ---

16R100 25 (7.6) 16R088 25 (7.6) 16R003 25 (7.6)

16R103 35 (10.7) 16R079 35 (10.7) 16R091 35 (10.7)

16R106 50 (15.2) 16R082 50 (15.2) 16R094 50 (15.2)

16R109 --- 16R085 --- 16R097 ---

16R205 25 (7.6) 16R006 25 (7.6) 16R193 25 (7.6)

16R208 35 (10.7) 16R184 35 (10.7) 16R196 35 (10.7)

16R211 50 (15.2) 16R187 50 (15.2) 16R199 50 (15.2)

16R214 --- 16R190 --- 16R202 ---

16R170 25 (7.6) 16R005 25 (7.6) 16R158 25 (7.6)

16R173 35 (10.7) 16R149 35 (10.7) 16R161 35 (10.7)

16R176 50 (15.2) 16R152 50 (15.2) 16R164 50 (15.2)

16R179 --- 16R155 --- 16R167 ---

ft (m) Part No.

Hose

Length

ft (m) Part No.

Hose

Length

ft (m)

4 3A2012J

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.

Accessories

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 Description

16M874

16M875

16M893 2 Gallon, ASME Solvent Flush Pressure Pot

16M894 5 Gallon, ASME Solvent Flush Pressure Pot

Heaters

Part Description

16N014★

16N015★

16N016

16N017

16N018

16N019

★

2 Gallon, ASME and CE-approved, Solvent Flush Pressure Pot

5 Gallon, ASME and CE-approved, Solvent Flush Pressure Pot

120V Viscon Heater, for hazardous locations

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 Description

16M712

16M718

16M719

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

25 ft Extension Hose Bundle for Chop Systems

25 ft Extension Hose Bundle for Internal Gel Systems

25 ft Extension Hose Bundle for External Gel Systems

3A2012J 5

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Engage trigger lock when not dispensing.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

6 3A2012J

Warnings

WARNING

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,

follow the Pressure Relief Procedure and disconnect all power sources.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and

follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

3A2012J 7

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information

MEKP is among the more hazardous materials found in commercial channels. Proper handling of the “unstable (reactive)” chemicals presents a serious challenge to the plastics industry. The highly reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins and gel-coats also produces the hazards which require great care and caution in its storage, transportation, handling, processing and disposal.

Workers must be thoroughly informed of the hazards that may result from improper handling of MEKP, especially in regard to contamination and heat. They must be thoroughly instructed regarding the proper storage, use and disposal of MEKP and other hazardous materials used in the laminating operation.

MEKP is flammable and potentially explosive, as well as potentially damaging to the eyes and skin.

Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to MEKP.

Contaminated MEKP can become explosive. Prevent contamination of MEKP with other materials, including but not limited to polyester overspray, polymerization accelerators and promoters, and non-stainless metals. Even small amounts of contaminates can make MEKP explosive. This reaction may start slowly, and gradually build-up heat, which can accelerate until fire or an explosion result. This process can take from seconds to days.

Heat applied to MEKP, or heat build-up from contamination reactions can cause it to reach what is called its Self-Accelerating Decomposition Temperature (SADT), which can cause fire or explosion. Spills should be promptly removed, so no residues remain. Spillage can heat up to the point of self-ignition. Dispose in accordance with manufacture’s recommendation.

Store MEKP in a cool, dry and well-ventilated area in the original containers away from direct sunlight and away from other chemicals. It is strongly recommended that the storage temperature remain below 86° F (30° C). Heat will increase the potential for explosive decomposition. Refer to NFPA 432. Keep MEKP away from heat, sparks and open flames.

Current catalysts are premixed and do not require any diluents. Graco strongly recommends that diluents not be used. Diluents add to the possibility of contaminates entering the catalyst system. Never dilute MEKP with acetone or any solvent since this can produce an extremely shock-sensitive compound which can explode.

Use only original equipment or equivalent parts from Graco in the catalyst system (i.e.: hoses, fittings, etc.) because a hazardous chemical reaction may result between substituted parts and MEKP.

To prevent contact with MEKP, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons and goggles are required for everyone in the work area.

8 3A2012J

Important Two-Component Material Information

Polyester Resins and Gel-Coats Spraying and Lamination Operations

Spraying materials containing polyester resin and gel-coats creates potentially harmful mist, vapors and atomized particulates. Prevent inhalation by providing sufficient ventilation and the use of respirators in the work area.

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

Changing Materials

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

Keep Resin and Catalyst Components Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange catalyst (usually MEKP) and resin (usually polyester resin or gel-coat) parts.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

3A2012J 9

Overview

The FRP proportioner dispenses pigmented, tooling, low-VOC, and specialty gel coats, as well as polyester resin and vinyl ester chemicals. The FRP proportioner supplies the individual catalyst and resin materials, and fiberglass roving to the gun. On internal mix systems, it also supplies solvent to the gun for clearing mixed material from the gun.

Typical Applications

• Marine and watercraft

• Pool and spa

•Bath ware

• Transportation

• Corrosion prevention

• Cultured marble

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

10 3A2012J

Component Identification

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

WLF

Key:

ACart BAir Motor C Resin Displacement Pump DCatalyst Pump E Solvent Flush (Diaphragm Pump Option Shown,

Pressure Pot Options also available)* F Catalyst Reservoir G Boom (not shown)

* Internal mix systems only.

3A2012J 11

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)

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: con- trols 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.

FRONT REAR

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.

ti21338a ti21339a

ABAG

. 1: Air Control Panel Components

Air Outlet Fitting

Details

Air Outlet 2 (AF) 3/8 tube 1/4 tube 3/8 tube 1/4 tube

Air Outlet 3 (AM) 1/4 tube 1/8 npt 3/8 tube 1/8 npt

Air Outlet 4 (AN)★ 1/2 tube 1/2 tube Plugged Plugged

Internal Chop External Chop Internal Gel External Gel

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

12 3A2012J

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 pres-

sure 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.

Component Identification

ti18499c

Fluid inlet (S): connect fluid suction hose to the 3/4 npt(m) fluid inlet.

DataTrak (T) (optional): electronic monitoring for material tracking, system diagnostics, and pump runaway control. The DataTrak is located on the air control panel. See the NXT Air Motor manual for details of the DataTrak controls and indicators.

FIG. 2

3A2012J 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 out-

let to the catalyst reservoir.

Low pressure relief valve (Z3): External mix systems only. Directs catalyst to gun or back to tank to relieve pressure.

ti21340a

ti21342a

. 3: Catalyst Pump Components

14 3A2012J

Solvent Flush Systems

Component Identification

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.

3/4 npt(f) Fluid

1/4 npt(f)

Outlet

Air Inlet

3/4 npt(f) Fluid Outlet

ti9078a1

. 4: Solvent Pump Components

Solvent Flush ASME Pressure Pot

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

ti18531a

The pressure pot works by using the incoming air pressure to expel the solvent in the pot out of the fluid outlet. Verify supply tube is installed on fluid outlet port.

Air Inlet Fill Cap Fluid Outlet

ti18530a

3A2012J 15

Setup

FRP proportioners are not approved for use in hazardous locations unless all accessories, all kits, and all wiring meet local, state, and national codes. See Agency Approvals on page 3.

This section provides instructions for basic system setup of the FRP proportioner. See the separate component manuals for detailed information.

Before Installation

• Have all system and component documentation

available during installation.

• If using a cart and boom system, ensure there is enough space overhead and surrounding the proportioner for the boom and mast to fully extend.

• Place on a flat and level surface.

System Mounting (Wall Mount Systems Only)

To reduce the risk of skin injection injury, make sure the system is depressurized before mounting any pump assembly. See the Pressure Relief Procedure and Shutdown on page 24.

For ease of operation and service, make sure the pump air inlet, fluid inlet, and fluid outlet ports are easily accessible. Mount the catalyst reservoir above the catalyst pump to enable gravity feed. Be sure the bracket is level.

• See component manuals for specific data on compo-

nent 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 81, for mounting and clearance dimensions.

Cart Mount Systems

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

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 reser-

voir mounting plate then each of the two upper pole clamps, then install and tighten nuts to secure mounting plate and clamps in place.

16 3A2012J

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 cata-

lyst reservoir mounting bracket to wall.

Setup

b. Use four bolts, washers, and nuts to install cata-

lyst reservoir onto the catalyst reservoir mounting bracket.

c. Use four bolts, washers, and nuts to secure

pumpline mounting bracket to wall.

d. Use four bolts, washers, and nuts to secure

pumpline to pumpline mounting bracket.

3A2012J 17

Setup

System Assembly

When the system is shipped from the factory some items may be shipped loose. Perform the following instructions to properly install each of the component items.

1. For cart and boom systems only, install legs:

a. With the system still on the pallet, use the sup-

plied hardware to install the legs onto the base as shown below. The two longer legs should be installed on the air control panel side of the machine. The two non-locking casters should be installed on the two longer legs.

2. Connect heater (if ordered):

• Improperly installed or connected equipment may create a hazardous condition that can cause fire, explosion, or electric shock.

• Refer to heater manual listed on page 3 for detailed instructions and warnings.

• You must have a qualified electrician connect heater wiring. Ensure wiring and installation comply with local electrical codes for hazardous areas.

• Wiring, wiring connections, switches, and electrical distribution panel must all meet flame-proof (explosion-proof) requirements.

a. Use supplied hardware to install heater onto

pole as shown below. Position the heater to ease hose routing between pump and heater. See Heater Kits manual for bolt hole patterns.

ti18523c

b. Use a forklift to raise the system off of the pallet,

remove the pallet, then place item directly on the floor.

Viscon Heater Shown

ti18529b

b. Connect heater electrical connections. See

heater manual listed on page 3 for detailed instructions.

18 3A2012J

Setup

3. Install solvent flush diaphragm pump or pressure pot (if ordered).

a. Use the supplied hardware to install the dia-

phragm pump or pressure pot onto the base of the cart in the mounting holes provided.

6. Use the supplied hardware to install the roving box bracket onto the pole. Install the top pole clamp above the lower arm of the boom as shown below (if ordered). If there is a second roving box, use long hex screws as shown below to secure mounting plate of second roving box to the mounting plate of the first roving box.

ti18525b

Solvent Flush Diaphragm Pump shown

ti18455c

b. Use supplied hardware to install solvent supply

tank onto the base of the cart.

4. Install DataTrak Upgrade Kit (if ordered). Follow the detailed instructions in DataTrak manual listed on page 3.

5. Assemble the boom as shown below then slide the boom onto the system pole (if ordered).

Spring

Chain

Roving Guides

Deflector Plates

ti18532b

3A2012J 19

Setup

Grounding

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current

General Grounding Guidelines

Pump: use ground wire and clamp (supplied). Connect

ground clamp to a true earth ground.

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.

FRP Proportioner Grounding

NOTE: All proportioners come with one grounding

clamp to ground the proportioner to a true earth ground. All accessories for internal mix systems come with a second grounding clamp to ground the solvent flush system to the cart.

1. Verify that the ground screw is attached and tightened securely to the air motor. Connect the other end of the ground wire to a true earth ground.

Ground

screw

Grounding wire

ti18454a

FIG. 5: Ground Wire

Object being sprayed: follow local code.

Solvent pails used when flushing: follow local code.

Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

2. For internal mix systems only, ground the solvent flush system.

a. For solvent flush diaphragm pumps only, con-

nect one end of the second grounding clamp to the solvent pump grounding strip. See the diaphragm pump manual listed on page 3 for grounding details.

b. Connect the other end of the grounding clamp

to the cart.

3. Use an ohmmeter to verify all components are grounded to the earth ground.

4. If wall power is used to power the heater, ground electrical connection according to local codes.

5. For cart proportioners: Connect the other end of the second supplied grounding clamp to the cart. For wall proportioners: Connect the other end of the second supplied grounding clamp to a true earth ground.

20 3A2012J

Setup

Connect Fluid and Air Lines

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)

Air (Chop/

Internal Gel

AAC)

. 6: Hose End Diagram

Solvent/ AAC Air

Catalyst

External Atomizing/ Internal Chop AAC Air

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

. 2 on page 13 and FIG. 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 sup- plied air tubing attached to air outlet 2 (AF) to atomized air line on gun. Internal mix proportioners only: Connect the supplied air tubing attached to air outlet 2 (AF) to solvent pump air inlet. See F

. 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.

FRONT REAR

ti21338a ti21339a

ABAG

FIG. 7: Air Control Panel Components

Air Outlet Fitting

Details

Air Outlet 2 (AF) 3/8 tube 1/4 tube 3/8 tube 1/4 tube

Air Outlet 3 (AM) 1/4 tube 1/8 npt 3/8 tube 1/8 npt

Air Outlet 4 (AN)

★

Internal Chop External Chop Internal Gel External Gel

1/2 tube 1/2 tube Plugged Plugged

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

3A2012J 21

Setup

Resin Pump and Optional Heater Connections

ti18499c

Catalyst Pump Fluid Connections

NOTE: See F

. 3 on page 14.

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

ti21343a

FIG. 9: Catalyst Pump Pressure Relief Valve

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

. 8

6. Verify the pressure relief/recirculation valve (P) is set to pressure relief.

7. Place a waste container below the fluid outlet then remove the pump fluid inlet cap. Drain the test oil then discard.

8. Connect resin suction hose to the resin pump 3/4 nptm fluid inlet (S). Place other end of suction hose in resin container.

9. For non-heated systems only: Connect resin hose from the gun hose bundle to the resin pump 1/4 nptf fluid outlet (R). Reducer fitting comes with Graco hose bundle. For heated systems only: attach resin hose from the gun hose bundle to the heater outlet. Verify fluid hose connecting resin pump outlet to heater inlet is installed and secure.

10. Connect resin recirculation hose to the pressure relief/recirculation line (P1) and route to the resin container.

22 3A2012J

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.

Setup

Flush Before First Use

Oil left in the system at the factory can react with catalyst and create a fire or explosion.

• Flush before first use.

• Do not add catalyst to the catalyst reservoir until the system has been flushed.

Flush the system before first use to prevent contaminating the resin or catalyst. See page 30.

Fill Supply Tanks

Add fluid to the solvent flush supply tank (if applicable), the catalyst supply reservoir, and the resin supply container.

3A2012J 23

Operation

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

ti18532b

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

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.

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.

. 10

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

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.

. 11

24 3A2012J

. 11.

Operation

5. Engage trigger lock.

. 12

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

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

FIG. 15

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.

. 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.

. 14

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

11. Perform the scheduled maintenance items listed on page 38.

3A2012J 25

Operation

Startup

NOTE: Do not exceed 20 psi (0.14 MPa, 1.4 bar) on the

material air pressure regulator until a steady material flow has been established.

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.

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.

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 sol-

vent will flow out of the front of the gun through

the dispense tip, then close the valve.

Oil left in the system at the factory can react with catalyst and create a fire or explosion.

• Flush before first use.

• Do not add catalyst to the catalyst reservoir until the system has been flushed.

4. If this is the first startup of the machine, perform the

Flush procedure on page 30.

26 3A2012J

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

Operation

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.

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 Shut-

down on page 24.

b. Remove the RS gun front end. See RS gun

manual list on page 3 if desired.

Never allow the pump to run dry of the fluid being pumped. A dry pump quickly accelerates to a high speed, possibly damaging itself and causing overpressurization and equipment rupture. If your pump accelerates quickly or is running too fast, stop it immediately and check the fluid supply. If the supply container is empty and air has been pumped into the lines, refill the container and prime the pump and the lines with fluid, or flush and leave it filled with a compatible solvent. Be sure to eliminate all air from the fluid system.

3. Units with runaway protection only: enable the

prime/flush function by pushing the prime/flush button on the DataTrak. This prevents the DataTrak from stopping the pump if it detects a high cycle rate.

4. Verify the pressure relief/recirculation valves on the catalyst pump is set to the pressure relief/recirculation position.

. 16

3A2012J 27

Operation

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

. 17

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

. 18.

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

. 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

. 18.

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

FIG. 20

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

. 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.

. 18

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.

. 19

To reduce the risk of fire and explosion, use a grounded pail.

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

. 21. The pump air pressure may need to

increase slightly until the material begins to flow.

. 21

28 3A2012J

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

. 22

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

Operation

. 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.

. 24

16. Units with runaway protection only: disable the prime/flush function by pushing the prime/flush button on the DataTrak.

17. Engage gun trigger lock.

18. If the front end of the gun was removed, apply grease to o-rings and front of gun to prevent material from curing or sticking to it, then install gun front end.

3A2012J 29

Operation

Flush

Oil left in the system at the factory can react with catalyst and create a fire or explosion.

• Flush before first use.

• Do not add catalyst to the catalyst reservoir until the system has been flushed.

To reduce the risk of fire and explosion and skin injection injury, only use a solvent compatible with the system wetted parts, the resin, and the catalyst.

Flush the system:

• Before first use

• When changing fluids

• Before repairing equipment

• Before fluid dries or settles out in a dormant pump (check the pot life of catalyzed fluids)

• Before storing the pump.

Flush at the lowest pressure possible. Flush with a fluid that is compatible with the fluid you are pumping and with the wetted parts in your system. Check with your fluid manufacturer or supplier for recommended flushing fluids and flushing frequency.

NOTE: Always flush catalyst pump separately by hand (remove pin from upper control arm and hand pump).

1. Remove all fluid inlet, recirculation, and weep lines from the catalyst reservoir and insert in a container filled with a compatible solvent.

2. Remove the resin pump fluid supply and recirculation lines from the resin supply container and insert in a container filled with a compatible solvent.

NOTICE

To prevent accidentally mixing resin and catalyst in the solvent container, there must be two solvent containers used, with the resin pump fluid lines inserted in one and the catalyst pump fluid lines inserted in the other.

3. With the fluid lines in the two separate solvent containers, perform the Prime procedure at the lowest pressure possible. While performing this procedure, leave the fluid supply, recirculation, and supply lines in the solvent containers.

30 3A2012J

Operation

Spray

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.

4. Turn the resin pump pressure relief/recirculation valve to the dispense position.

FIG. 26

5. Turn the catalyst pump pressure relief/recirculation valve to the dispense position. See F

. 27.

6. Bring catalyst pump fluid outlet line to dispensing pressure (see F

. 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.

. 27

FIG. 25

3A2012J 31

Operation

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

. 28.

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

reads the desired pressure. See F

. 28

9. Disengage trigger lock on the gun. See F

10. Pull trigger to begin dispensing. See F

. 28.

. 29.

NOTE: In the following step, to minimize catalyst overspray, use as little catalyst atomization air pressure as possible to achieve desired spray pattern. See the spray gun manual for instructions.

11. If the spray pattern has not already been set up to perform as desired, see RS gun manual for detailed instructions for how to optimize the spray pattern, including adjusting the AAC air pressure at the system or gun, and adjusting the catalyst atomization air.

no air too little air

correct amount

of air

FIG. 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.

. 29

13. For internal mix proportioners only: When finished spraying engage trigger lock then point the gun into a waste container and use the solvent knob on the gun to move solvent through the gun to flush the gun.

14. For external mix proportioners only: When finished spraying, squirt the tip of the gun with solvent to remove any mixed material.

15. If necessary, use a brush to remove cured material from front of the gun.

16. If finished spraying for an extended period of time:

Follow Pressure Relief Procedure and Shutdown on page 24.

32 3A2012J

DataTrak Operation

Operation

For DataTrak installation instructions, see NXT Air motor for FRP manual.

NOTICE

To prevent damage to the soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

Controls and Indicators

NOTE: See FIG. 31. The display (Y) will turn off after 1 minute of inactivity in Run mode or 3 minutes in Setup mode.

Press any key to wake up the display. DataTrak will continue to count cycles when display is off.

Run Mode

CF; See Details at right.

TI8622b

*CB

TI11883a

FIG. 31. DataTrak Controls and Indicators

Key:

CA Runaway Limit, in cycles per minute (user settable;

00=OFF)

CB * Lower Displacement (user settable)

CC Flow Rate Units (user settable to gpm [US],

gpm [Imperial], oz/min [US], oz/min [Imperial], l/min, or

cc/min) CD LED (fault indicator when lit) CE Diagnostic Reference Card (see Table 1, page 37) CF Display

/min,

Setup Mode

PF Prime/Flush Key (Enables Prime/Flush mode. While in

Prime/Flush mode, runaway protection is disabled and the batch totalizer (BT) will not count.)

RK Reset Key (Resets faults. Press and hold for 3 seconds to

clear the batch totalizer.) CF Cycle/Flow Rate BT Batch Totalizer GT Grand Totalizer RT Runaway Toggle (enable/disable) UT E1 Error Option (enable/disable) DT E2 Error Option (enable/disable) ST E5 Error Option (enable/disable)

TI8623b

3A2012J 33

Operation

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

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

34 3A2012J

Setup Mode

Operation

1. See FIG. 31. Press and hold for 5 seconds until Setup menu appears.

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

2. Runaway Screens 1 and 2: To reset the runaway

. 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.

solenoid, close the master air valve (AP). Wait for air to completely bleed off the air motor.

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

31.

3. Move the cursor to the E5 error enable option field,

then press once more to exit Setup mode.

ti11902a

FIG. 32. Solenoid Release Button

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.

4. Runaway Screens 5 and 6: Press to clear the diagnostic code and reset the runaway solenoid.

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) (see F

. 31).

3A2012J 35

Operation

Prime/Flush

1. See F

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

will stop flashing.

Counter/Totalizer

See F

. 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.

Display

See F

. 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

. 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

• If AC is set to gallons or ounces, BT and GT display gallons.

• If AC is set to liters or cc, BT and GT display liters.

• If AC is set to cycles, BT and GT display cycles.

Press to toggle between flow rate units and cycles. A letter under the BT display indicates that both BT and

GT are displaying gallons (g) or liters (l). No letter means both BT and GT are displaying cycles.

36 3A2012J

Table 1: Diagnostic Codes

Symbol Code Code Name Diagnosis Cause

Runaway (DataTrak only)

E-1 Diving Up Leak during upstroke. Worn piston valve or packings.

E-2 Diving Down Leak during downstroke. Worn intake valve.

Pump running faster than set runaway limit.

•

Increased air pressure.

•

Increased fluid output.

•

Exhausted fluid supply.

Operation

E-3 Low Battery Battery voltage too low to stop

runaway.

E-4 Service

Component 1 (units with runaway protection only)

E-4 Disconnected

Solenoid (units with runaway protection only)

E-5 Service

Component 2

E-6 Blown Fuse Fuse is blown. Replace fuse;

Problem with stopping runaway.

Solenoid is disconnected.

Solenoid is not engaging piston cup.

Problem with sensing valve movement.

see page 38.

Low battery. Replace battery; see page 38.

•

Damaged solenoid.

•

Damaged valve carriage.

•

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

•

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

3A2012J 37

Operation

Replace DataTrak Battery or Fuse

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

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

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

2. Remove the cable from the two cable clips.

. 33.

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

. 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

. 33. Disconnect DataTrak

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

Battery

ti11994a

FIG. 34. DataTrak Battery and Fuse Location

38 3A2012J

Maintenance

Task Schedule

Maintenance

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

Daily

Weekly

As needed

Components

See component manuals listed on page 3 for maintenance schedules and procedures for each component.

3A2012J 39

Troubleshooting

Follow Pressure Relief Procedure and Shutdown on page 24 before checking or servicing the equipment.

Problems

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs.

Catalyst Pump

See Catalyst Slave Pumps parts illustration on page 66 for parts identification.

Problem Cause Solution

Pressure loss on up stroke. Worn transfer housing seal. Replace transfer housing seal.

Worn transfer housing seat. Replace transfer housing.

Pressure loss on up stroke and down stroke.

Pressure not building on up stroke. Damaged transfer housing seat. Replace transfer housing.

Pressure not building on down stroke. Scratched inlet valve. Replace inlet valve.

Leakage from cartridge housing. Loose cartridge housing. Tighten cartridge housing.

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

Pump will not prime. Fluid inlet ball valve is closed. Open fluid inlet ball valve.

Excessive weepage Missing snap-on seal retainer Remove cartridge and install

Worn weep seals. Replace weep cartridge.

Blow off valve spring is wearing out. Replace blow off valve.

Loose fittings on spray gun and/or hoses. Tighten fittings on spray gun and hoses.

Scratched piston rod. Replace piston rod.

Loose bearing. Tighten bearing.

Relief valve or check valve has a weak spring.

Worn or damaged snap-on seal retainer Remove and replace

Replace relief valve or check valve.

Resin Pump

See Resin Pumplines on page 61 for parts identification.

Problem Cause Solution

Does not operate. Valve closed or clogged. Clear air line; increase air supply. Check that

valves are open.

Fluid hose or gun obstructed. Clean hose or gun.*

Dried fluid on displacement rod. Clean rod; always stop pump at bottom of stroke;

keep wet-cup filled with Throat Seal Liquid (TSL).

Air motor parts dirty, worn, or damaged. Clean or repair air motor. See air motor manual.

Runaway error on DataTrak tripped (if DataTrak installed)

Stall on bottom of stroke.

40 3A2012J

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

See DataTrak Operation-Runaway Monitor, page 35.

Runaway, page 35, to reset the runaway solenoid.

Troubleshooting

Problem Cause Solution

Output low on both strokes.

Pump output low on only one stroke.

No output. Improperly installed ball check valves. Check and repair.

Pump operates erratically.

Erratic accelerated speed.

Runs sluggishly. Possible icing. See air motor manual for instructions.

Cycles or fails to hold pressure at stall.

Air bubbles in fluid. Loose suction line. Tighten. Use compatible liquid thread sealant or

Poor finish or irregular spray pattern.

Difficulty priming Inlet ball stuck to seat Tap pump with hammer to dislodge.

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

Fluid hose/gun obstructed. Clear hose or gun*.

Air motor icing. See air motor manual for instructions.

Exhausted fluid supply. Refill and prime pump.

Worn piston packings. Replace.

Open or worn intake valve. Clear or service intake valve.

Held open or worn ball check valves. Check and repair.

Worn piston packings. Replace.

Exhausted fluid supply. Refill and reprime pump.

Held open or worn ball check valves. Check and repair.

Worn piston packing. Replace.

Suction tube too restrictive, causing pump to cavitate

Fluid supply exhausted, clogged suction. Refill supply and prime pump. Clean suction tube.

High viscosity fluid. Reduce viscosity; increase fluid temperature,

Open or worn piston valve or seal. Clear piston valve; replace seal.

Open or worn intake valve. Clear or service intake valve.

Filler material clumping causing extra friction on rods and seals.

Worn check valves or seals. Service lower. See lower manual for instructions.

Incorrect fluid pressure at gun. See gun manual; read fluid manufacturer’s recom-

Fluid is too thin or too thick. Adjust fluid viscosity; read fluid manufacturer’s rec-

Dirty, worn, or damaged spray gun. Service spray gun. See spray gun manual.

Suction hose/strainer too restrictive or clogged Clean inlet strainer, shorten hose length and/or

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

Use larger diameter tube

reduce flow rate by using smaller tip.

Flush pump and replace packings.

PTFE tape on connections.

mendations.

ommendations.

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

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.

3A2012J 41

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 Shut- down 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.

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 the coupling nut (A). Use a magnet to aid removing the two collars (B).

ti12815a

General Information

• Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing.

• Always use Genuine Graco Parts and Accessories, available from your Graco distributor. If you supply your own accessories, be sure they are adequately sized, pressure rated, and made of materials compatible with your system.

Disconnect the Displacement Pump

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

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.

ti12813a

ti12816a

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.

42 3A2012J

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

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

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.

6. Gently let the air motor piston rod drop onto the displacement rod. Hand tighten the coupling nut (A).

ti12817a

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.

7. Screw the displacement pump into the adapter plate (D) until the cylinder top is flush with the top of the adapter plate.

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

ti12814a

. 35. Align cylinder and adapter plate.

3A2012J 43

Repair

Disconnect the Air Motor

See manual 3A2315 for air motor service and parts information. See F

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).

. 36 on page 45.

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 FIG. 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.

ti12817a

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

ti12812a

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

ti12813a

8. Attached grounding wire to true earth ground.

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

44 3A2012J

Repair

FIG. 36

ti18456c

3A2012J 45

Repair

Replace Pumpline

This procedure is only needed if the entire pumpline will be replaced. If just installing repair parts in the air motor and/or displacement pump, see Disconnect the Dis-

placement Pump on page 42, Disconnect the Air Motor on page 44, displacement pump manual 3A2313,

and air motor manual 3A2315.

1. Flush the pump, see page 30.

2. Relieve the pressure, see page 24.

3. Disconnect main air line from air panel (AE).

4. Disconnect items from the air motor, see F 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).

. 36 on

8. Use a socket to remove the two screws (AK) securing the displacement pump to the mounting bracket.

9. Lift up on the pumpline to slide pumpline out of bracket.

10. Reassembly is reverse of assembly.

46 3A2012J

Repair

Repair Catalyst Pump

See FIG. 37 on page 49 for reference numbers.

Remove Catalyst Pump from System

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.

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.

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.

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

3A2012J 47

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).

Repair

30. Hold spring (911) upright, place valve (912) on top of spring, slide transfer housing (914) upside down over the spring then flip upright.

31. Install transfer housing (914) onto piston rod (910). Use flats on rod and transfer housing to torque transfer housing against the piston rod to 30-50 in-lb (3.4-5.6 N•m).

32. Slide the cartridge (902) down against the transfer housing (914).

33. Install u-cup (915) onto transfer housing with u-cup opening facing up towards the rod.

34. Install guide (916) onto transfer housing.

35. Install transfer housing cap (917) onto transfer housing. Use flats to torque to 30-50 in-lb (3.4-5.6 N•m).

Repair Foot Valve

36. Use wrench to loosen lock nut (921) then remove cylinder (918) from foot valve (922).

37. Remove ball (925) from foot valve.

38. Remove backup o-ring (920) and o-ring (919) from both ends of the cylinder (918).

39. Remove ball seat (923). Tool 24N253 can be used to aid ball seat removal.

40. Place new ball seat onto seat installation tool 16N996 with lip opening facing in towards tool.

Assemble Catalyst Pump

46. Verify cartridge (902) is pressed against the transfer housing (914).

47. Lubricate the o-ring (902g) on the cartridge.

48. Apply thread sealant to the threads of the cartridge (902a).

49. With the slave pump housing (901) in a vise, carefully thread the cartridge (902) into the housing. Torque the cartridge to 240 in-lb (27.1 N•m).

50. Lubricate the o-rings (919, 920) on the cylinder (918).

51. Hand-thread the cylinder (918) into the slave pump housing (901) all the way until the cylinder bottoms out. Rotate the cylinder counterclockwise less than 1/2 turn until the flat on the cylinder is parallel with the quick-release pin hole then insert the quick-release pin (908).

52. With the quick-release pin in place, rotate the foot valve counterclockwise less than one full-turn so that it is facing directly backwards relative to the pressure gauge.

53. Hold the foot valve in position and tighten the lock nut (921) against the foot valve to 225-275 in-lb (25.4-31.1 N•m).

54. Push the piston rod (908) down into the slave pump housing (901).

41. Place tool into foot valve then tap with a hammer until ball seat is properly seated then remove tool.

42. Install new backup o-ring (920) and o-ring (919) onto both ends of the cylinder (918). Make sure to install the o-rings in the correct position, with the backup o-rings towards the center of the cylinder.

43. Lubricate the backup o-rings (920) and o-rings (919).

44. Install ball into foot valve.

45. Thread cross-cut end of cylinder into foot valve by hand until it bottoms out but do not tighten the jam nut.

48 3A2012J

Repair

929 927

946

935

909

907

909

919

920

921

Internal Mix shown

922

924

External Mix Only

908

947

928

902d

926

910

902

901

932

1 4

947

902b

902f

902a

902g 902f

903

903a

ti19060a

902e

911

912 913

914

945

ti21344a1

903b

Apply pipe sealant to threads.

Apply thread locker to mating surfaces or threads.

Apply grease to mating surfaces or threads.

Torque to 240 in-lb (27.1 N•m).

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

Loop large end of lanyard over gauge prior to assembling gauge. Attach small end of lanyard to

split ring on pin.

Note orientation of u-cup.

Torque to 30-50 in-lb (3.4-5.6 N•m).

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).

Press fit bearings.

Torque piston rod (910) to top link (926) to 80-100 in-lb (9.0-11.3 N•m).

Torque to 20 - 60 in-lb (2.3-6.8 N•m).

Snap 902e onto 902a.

915

916

917

918

903c

920

919

925

923

940

930

924

932

946

939

934

938

939

947

937

FIG. 37: Catalyst Pump Details

3A2012J 49

System Parts

Systems

121

107

106

5 4

152

111

105

110

113

104

109

103

114,115,116

108

104

102

108

113

122

ti19056b

Loosen grounding lug locknut and washer, insert grounding wire into slot in lug and tighten locknut securely.

Apply grease to outer diameter, not to the threads.

Torque to 45-55 ft-lb (61-75 N•m).

Connect tubing to catalyst pump.

Torque to 20-30 ft-lb (27-41 N•m).

50 3A2012J

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. Part Description

102 16N918 WALL OR POLE MOUNT KIT

(No Cart)

--- CART, for use with boom 11 1111

--- CART 11 11111

103 W13DFCPUMP, FRP, 13:1 1111 1111111

W17CFS PUMP, FRP, 17:1 1 1 104 111799SCREW, cap, hex head 6666666666666 105 16P125 HARNESS, slave linkage 1 111111111111 106 119999BOLT, shoulder 1111111111111 107 24M092PIN, quick release, 1.5 x 0.25 1111111111111 108 16N741PUMP, slave, external mix 1 1 1 1111111

16N740 PUMP, slave, internal mix 1 1 1 109 120476BOLT, shoulder, 5/16 1111111111111 110 111040NUT, lock, insert, nylock, 5/16 1111111111111 111 16M564 LABEL, ratio, 13:1, FRP 1 1 1 1 1 1 1 1111

16M565 LABEL, ratio, 17:1, FRP 1 1 112◆ 16N761BOOM KIT 11 1111 113 16U750PANEL, air control 1111111111111 114 113093FITTING, connector, 1/4 nptf 1111111111111 115 114109 FITTING, elbow, male, swivel 1

121141 FITTING, elbow, swivel, 3/8t 1/4mnpt 2 2

16D939FITTING, nipple, reducing 1 1 1 1111111 116 114109FITTING, elbow, male, swivel 1 1 1 1111111

121141 FITTING, elbow, male, swivel 1 118 --- TUBING, nylon, round 3 3 3 119◆ 238909WIRE, grounding 1111111111111 121 --- TUBE, nylon, round 3333333333333 122 124071PLUG, fitting, push-to-connect 11 111111111 123◆ 16M588 HOSE, bundle, 25 ft external gel 1 1 1

16M587 HOSE, bundle, 25 ft internal gel 1 1 16M586 HOSE, bundle, 25 ft chop 1 1 16M591 HOSE, bundle, 35 ft external gel 1 1 16M590 HOSE, bundle, 35 ft internal gel 16M589 HOSE, bundle, 35 ft chop 16M585 HOSE, bundle, 50 ft external gel 1 1 16M584 HOSE, bundle, 50 ft internal gel 16M583 HOSE, bundle, 50 ft chop

124◆ 258970 GUN, external mix, chop, with cutter 1

258840 GUN, external mix, gel 1 1 1 1 1 1 1

258971 GUN, internal mix, chop, with cutter 1

258853 GUN, internal, gel 1 1 125◆ 16M736SUPPLY HOSE, 55 gallon 1111111111111 126◆ 16M810KIT, FRP 1111111111111 151◆ ▲ 16D136 LABEL, warnings 1 111111111111

16R001

16R002

16R003

16R004

16R005

16R006

16R009

16R012

16R015

16R018

16R021

16R024

16R027

152 24M692SPACER, ball joint 1111111111111

◆ Item not shown.

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

3A2012J 51

System Parts

Ref. Part Description

102 16N918 WALL OR POLE MOUNT KIT

16R030

16R033

16R036

16R039

16R044

16R047

16R050

16R053

16R056

16R059

16R062

16R065

16R068

16R071

1111 1111

16R074

16R079

16R082

16R085

16R088

16R091

16R094

(No Cart)

--- CART, for use with boom 1 1 1 1 1 1 1

--- CART 111 1111

103 W13DFC PUMP, FRP, 13:1 1111111111111111111111

W17CFS PUMP, FRP, 17:1 104 111799 SCREW, cap, hex head 6 6 6 6666666666666666666 105 16P125 HARNESS, slave linkage 1111111111111111111111 106 119999 BOLT, shoulder 1111111111111111111111 107 24M092 PIN, quick release, 1.5 x 0.25 1111111111111111111111 108 16N741 PUMP, slave, external mix 1111 1111111

16N740 PUMP, slave, internal mix 11111111111 109 120476 BOLT, shoulder, 5/16 1111111111111111111111 110 111040 NUT, lock, insert, nylock, 5/16 1111111111111111111111 111 16M564 LABEL, ratio, 13:1, FRP 1111111111111111111111

16M565 LABEL, ratio, 17:1, FRP 112◆ 16N761 BOOM KIT 1 1 1 1 1 1 1 113 16U750 PANEL, air control 1111111111111111111111 114 113093 FITTING, connector, 1/4 nptf 1111111111111111111111 115 114109 FITTING, elbow, male, swivel

121141 FITTING, elbow, swivel, 3/8t

22222222222

1/4mnpt

16D939 FITTING, nipple, reducing 1111 1111111

116

114109 FITTING, elbow, male, swivel 1111 1111111

121141 FITTING, elbow, male, swivel 118 --- TUBING, nylon, round 33333333333 119◆ 238909 WIRE, grounding 1111111111111111111111 121 --- TUBE, nylon, round 3333333333333333333333 122 124071 PLUG, fitting, push-to-connect 111111111111111 123◆ 16M588 HOSE, bundle, 25 ft external gel 1

16M587 HOSE, bundle, 25 ft internal gel 1 1 16M586 HOSE, bundle, 25 ft chop 1 16M591 HOSE, bundle, 35 ft external gel 1 16M590 HOSE, bundle, 35 ft internal gel 1 1 1 16M589 HOSE, bundle, 35 ft chop 1 1 16M585 HOSE, bundle, 50 ft external gel 1 16M584 HOSE, bundle, 50 ft internal gel 1 1 1 16M583 HOSE, bundle, 50 ft chop 1 1

124◆ 258970 GUN, external mix, chop, with cutter 1 1 1 1 1

258840 GUN, external mix, gel 1 1 1

258971 GUN, internal mix, chop, with cutter

258853 GUN, internal, gel 1 1 1 1 1 1 1 1 125◆ 16M736 SUPPLY HOSE, 55 gallon 1111111111111111111111 126◆ 16M810 KIT, FRP 1111111111111111111111 151◆ ▲ 16D136 LABEL, warnings 1111111111111111111111 152 24M692 SPACER, ball joint 1111111111111111111111

◆ Item not shown.

16R097

▲ Replacement Danger and Warning labels, tags and

cards are available at no cost.

52 3A2012J

System Parts

Ref. Part Description

102 16N918 WALL OR POLE MOUNT KIT

16R100

16R103

16R106

16R109

16R114

16R117

16R120

16R123

16R126

16R129

16R132

16R135

16R138

16R141

1111 1111

16R144

16R149

16R152

16R155

16R158

16R161

16R164

(No Cart)

--- CART, for use with boom 111 1111

--- CART 1111 111

103 W13DFC PUMP, FRP, 13:1 111111111111111

W17CFS PUMP, FRP, 17:1 1111111 104 111799 SCREW, cap, hex head 6666666666666666666666 105 16P125 HARNESS, slave linkage 1111111111111111111111 106 119999 BOLT, shoulder 1111111111111111111111 107 24M092 PIN, quick release, 1.5 x 0.25 1111111111111111111111 108 16N741 PUMP, slave, external mix 1111 1111111

16M565 LABEL, ratio, 17:1, FRP 1111111 112◆ 16N761 BOOM KIT 111 1111 113 16U750 PANEL, air control 1111111111111111111111 114 113093 FITTING, connector, 1/4 nptf 1111111111111111111111 115 114109 FITTING, elbow, male, swivel 11111111111

121141 FITTING, elbow, swivel, 3/8t

1/4mnpt

16D939 FITTING, nipple, reducing 1111 1111111

116

114109 FITTING, elbow, male, swivel 1111 1111111

121141 FITTING, elbow, male, swivel 11111111111 118 --- TUBING, nylon, round 33333333333 119◆ 238909 WIRE, grounding 1111111111111111111111 121 --- TUBE, nylon, round 3333333333333333333333 122 124071 PLUG, fitting, push-to-connect 1111111 123◆ 16M588 HOSE, bundle, 25 ft external gel 1

16M587 HOSE, bundle, 25 ft internal gel 16M586 HOSE, bundle, 25 ft chop 1 1 1 16M591 HOSE, bundle, 35 ft external gel 1 1 16M590 HOSE, bundle, 35 ft internal gel 16M589 HOSE, bundle, 35 ft chop 1 1 1 1 16M585 HOSE, bundle, 50 ft external gel 1 1 16M584 HOSE, bundle, 50 ft internal gel 16M583 HOSE, bundle, 50 ft chop 1 1 1 1

124◆ 258970 GUN, external mix, chop, with cutter 1 1 1

258840 GUN, external mix, gel 1 1 1 1 1

258971 GUN, internal mix, chop, with cutter 1 1 1 1 1 1 1 1

258853 GUN, internal, gel 125◆ 16M736 SUPPLY HOSE, 55 gallon 1111111111111111111111 126◆ 16M810 KIT, FRP 1111111111111111111111 151◆ ▲ 16D136 LABEL, warnings 1111111111111111111111 152 24M692 SPACER, ball joint 1111111111111111111111

◆ Item not shown.

16R167

▲ Replacement Danger and Warning labels, tags and

cards are available at no cost.

3A2012J 53

System Parts

Ref. Part Description

102 16N918 WALL OR POLE MOUNT KIT

16R170

16R173

16R176

16R179

16R184

16R187

16R190

16R193

16R196

16R199

16R202

16R205

16R208

16R211

1111 1111

16R214

(No Cart)

--- CART, for use with boom

--- CART

111

1111

103 W13DFC PUMP, FRP, 13:1

W17CFS PUMP, FRP, 17:1 104 111799 SCREW, cap, hex head 105 16P125 HARNESS, slave linkage 106 119999 BOLT, shoulder 107 24M092 PIN, quick release, 1.5 x 0.25 108 16N741 PUMP, slave, external mix

16N740 PUMP, slave, internal mix 109 120476 BOLT, shoulder, 5/16 110 111040 NUT, lock, insert, nylock, 5/16

111111111111111 666666666666666 111111111111111 111111111111111 111111111111111 1111

11111111111 111111111111111 111111111111111

111 16M564 LABEL, ratio, 13:1, FRP

16M565 LABEL, ratio, 17:1, FRP 112◆ 16N761 BOOM KIT 113 16U750 PANEL, air control 114 113093 FITTING, connector, 1/4 nptf

111111111111111

1111 111111111111111 111111111111111

115 114109 FITTING, elbow, male, swivel

121141 FITTING, elbow, swivel, 3/8t

22222222222

1/4mnpt

1111 1111

116

16D939 FITTING, nipple, reducing

114109 FITTING, elbow, male, swivel

121141 FITTING, elbow, male, swivel 118 --- TUBING, nylon, round 119◆ 238909 WIRE, grounding 121 --- TUBE, nylon, round 122 124071 PLUG, fitting, push-to-connect 123◆ 16M588 HOSE, bundle, 25 ft external gel

16M587 HOSE, bundle, 25 ft internal gel

111111111111111 333333333333333 111111111111111 1

33333333333

11 16M586 HOSE, bundle, 25 ft chop 16M591 HOSE, bundle, 35 ft external gel 16M590 HOSE, bundle, 35 ft internal gel

111 16M589 HOSE, bundle, 35 ft chop 16M585 HOSE, bundle, 50 ft external gel 16M584 HOSE, bundle, 50 ft internal gel

111

16M583 HOSE, bundle, 50 ft chop

124◆ 258970 GUN, external mix, chop, with cutter

258840 GUN, external mix, gel

111 258971 GUN, internal mix, chop, with cutter 258853 GUN, internal, gel

125◆ 16M736 SUPPLY HOSE, 55 gallon 126◆ 16M810 KIT, FRP 151◆ ▲ 16D136 LABEL, warnings

111111111111111

11 111 111

152 24M692 SPACER, ball joint 111111111111111

◆ Item not shown.

▲ Replacement Danger and Warning labels, tags and

cards are available at no cost.

54 3A2012J

Carts

System Parts

201

202

203

205

211 207

208 209

Ref Part Description

201 --- CART, chop 1

--- CART, pole 1 202 16P425 RESERVOIR, gravity feed, 2.5 gallon 1 1 203 100023 WASHER, flat 4 4 204 110837 SCREW, flange, hex 4 4 205 111040 NUT, lock, insert, nylock, 5/16 4 4 207◆ 16V707 BUSHING, filter, tank 1 1 208◆ 16V703 FITTING, 3/8 tube x 1/4 npt; sst 1 1 209 --- TUBE, polyethylene, 0.375 OD 1.5 1.5 210 --- TUBE, polyethylene, 0.250 OD 5 5 211◆ 16V733 FILTER, tip (3-pack) 1 1 221 16M465 CASTER, locking (not shown) 2 4 222 113962 WASHER (not shown) 4 223 100321 NUT (not shown) 4 224 122051 CASTER, non-locking (not shown) 2

204

210

1 1

Quantity

Cart, for

use with

boom

Cart, not

for use

with boom

Apply sealant to threads.

◆ Included in Catalyst Outlet Kit 16N854.

3A2012J 55

System Parts

56 3A2012J

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

312

301

305,306,307,308

System Parts

309,310,311

303

304

Pole not included

Ref Part Description Qty

301 16M666 BRACKET, pump, pole mount 1 302 16M466 BRACKET, catalyst tank 1 303◆ --- CLAMP, pipe, set 4 304◆ --- PLATE, cover, clamp 4 305◆ --- SCREW, cap, hex head 8 306◆ --- WASHER, hardened, sae 8 307◆ --- NUT 8 308◆ --- WASHER, lock, spring 8 309 110837 SCREW, flange, hex 4 310 100023 WASHER, flat 4 311 111040 NUT, hex 4 312 111799 SCREW, cap, hex head 4

◆ Included in pipe clamp kit 16P291.

ti18528c

3A2012J 57

System Parts

Boom, 16N761

401

411

413

ti19076a

Item shown for reference only.

2 in. ID schedule 40 pipe not included.

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

407

Ref Part Description Qty

401 --- SUPPORT, boom, mast 1 402◆ 22546-00 STRAP, binding, rubber, reusable 10 403 16M626 COVER, roving, guides 5 404 22486-00 GUIDE, roving, ceramic 12 405 100016 WASHER, lock 12 406 100015 NUT, hex mscr 12 407 100103 PIN, cotter 1 408 16M811 CHAIN, spring, boom 1 409 112248 NUT, hex 1 410 105170 SCREW, cap hex head 1 411 444 SPRING, boom 1 412 555626 WASHER, 1/4 plain flat big 2 413 16M808 PIN, clevis with cotter pin 1 414 16N950 EXTENSION, boom 1

412

410

409

408

412

401

414

406

405

404

403

◆ Not shown.

--- Not for sale.

58 3A2012J

Air Panel

System Parts

512

501

510

533

505

517

503

506

529

525

502

522

509

Plug supplied with regulator (504).

Apply sealant to all non-swiveling pipe threads.

511

510

537

542

520

538

521

515

531

541

504

509

522

527

504

509

522

540

539

514

ti19058b

519

Ref Part Description Qty

501 --- PANEL, air control 1 502 15T536 REGULATOR, air, 3/8 npt 1 503 15T538 NUT, regulator 1 504 116513 REGULATOR, air 2 505 116514 NUT, regulator 2 506 15T500 GAUGE, pressure, air, 1/8 3 509 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

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

3/8 npt(m) 517 16U556 LABEL, air control panel, FRP 1 519 124071 PLUG, fitting, push-to-connect 1 520 --- TUBING, air, 3/8 in. OD;

0.18

polyurethane

Ref Part Description Qty

521 --- TUBE, polyethylene; 1/2 in. OD 0.68 522 --- TUBE, nylon, round, black 1.37 525 114381 SCREW, cap, button head 3 527 124496 VALVE, air check 1 529 --- BRACKET, air control 1 531 113498 VALVE, safety, 110 psi 1 533 --- INSERT, control panel 1

537

538

539

96/0005-

WASHER, lock, ext, #10, ms 2

2/99 16U452 FITTING, elbow, 1/4npt(m) x

1/2 tube

16U479 FITTING, cross, 1/2 tube,

plastic

540

541

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

plastic

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

1/4 npt(f)

542

105332 NUT, lock 2

3A2012J 59

System Parts

Slave Pump Linkage, 16P125

2001d

2001a

2005

2006

2007

2008

2002

2003 2004

2001f

ti19057a

2001e

2001c

2001b

Ref Part Description Qty

2001 --- HARNESS, slave linkage 1 2001a 16N776 KIT, upper link, slave 1 2001b 16N775 KIT, lower link, slave 1 2001c 119999 BOLT, shoulder 1 2001d 116969 NUT, lock 1 2001e 7486-05 WASHER, flat, standard, #10 1 2001f 7486-03 WASHER, flat, fender, 1/4 1 2002 16M362 LINK, fixed, pivot 1 2003 116596 SCREW, cap, hex head 2 2004 119999 BOLT, shoulder 1 2005 16N774 LINK, yoke, upper, assy 1 2006 24M092 PIN, quick release, 1.5 x 0.25 1 2007 111040 NUT, lock, insert, nylock, 5/16 1 2008 120476 BOLT, shoulder, 5/16 1

Ratio Indicator labels (111), 75cc (16M565) and 100cc (16M564), are not included. Purchase separately.

60 3A2012J

Resin Pumplines

System Parts

615

613

602

616

606

607

608

603

605

604

612

Torque to 50-55 ft-lb (68-75 N•m).

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).

Torque to 250 in-lb (28.2 N•m)

Torque to 70-75 ft-lb (95-102 N•m).

Torque to 75-80 ft-lb (102-108 N•m).

Apply thread sealant.

609

617 614

601

610

611

618

Ref Part Description

601 M07LNL MOTOR, double

Quantity

W13DFC,

13:1

1 1

W17CFS,

17:1

ended, 4.5 in.

602* 15M662 ROD, tie 3 3

603* 16U435 ADAPTER, dis-

placement pump

16U426 ADAPTER, dis-

placement pump

604 LW100C PUMP, 100 cc 1

LW075S PUMP, 75 cc 1

605* 15U606 NUT, lock, M16 x 2 3 3

606*† 24A619 COLLAR, coupling

2 2

(10 pack)

607* 15T311 NUT, coupler 1 1

608* 24A625 RESERVOIR, TSL,

1 75cc lower (includes 618)

24A626 RESERVOIR, TSL,

1 100cc lower (includes 618)

609 16N774 LINK, yoke, upper 1 1

610 16M362 LINK, fixed, pivot 1 1

611 116596 SCREW, cap, hex

2 2 head

612 24F620 FILTER, fluid,

1 1 5000 psi

613 24D642 MUFFLER 1 1

614 100361 PLUG, pipe 1 1

615 16M355 FITTING, adapter,

1 1 muffler, 1/2 npt x 1in. - 14

616* 16M477 SPRING, guard 1 1

617 15V204 FITTING, elbow,

1 1 1/2 npt x 1/2 tube

618*† --- O-RING, wetcup 1 1

* Included in Connecting Kit. See page 62 to order the

correct kit for your pump.

†See Resin Pumpline Kits on page 62.

3A2012J 61

System Parts

Resin Pumpline Kits

Kit Description LW075S LW100C

Wet-Cup O-Ring (618)

Package of 10 24A631 24A632

Coupling Collars (606)

Package of 10

Connecting Kit

Includes pump adapter (603), three tie rods (602), three tie rod nuts (605), TSL reservoir (608) and TSL bottle, adapter (603), coupling nut (607), three coupling collars (606), tie rod spring guard (616).

NOTE: For displacement pump repair kits, see manual 3A2313. For air motor repair kits, see manual 3A2315.

Air Motor and Pump for Resin Pumpline

See air motor manual 3A2313 and pump manual 3A2315 for parts identification.

24A619 24A619

16N242 16N243

Gun

See RS gun manual 3A0232 for parts identification.

62 3A2012J

Resin Filter

24F620

System Parts

706

703

720

704

705

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 Qty

701 24C501 BOWL, filter 1 702 171942 HEAD, filter 1 703 238635 VALVE, ball, carbon steel 1 704 205447 COUPLING, hose 1 705 --- HOSE, nylon, 225 psi 7 706 100509 PLUG, pipe 1 707 104361 PACKING, o-ring 1 708 186075 SUPPORT, filter 1 710 171941 SPRING, compression 1 711 100040 PLUG, pipe 1 717▲ 172479 TAG, warning (not shown) 1 718 GC2069 FITTING, swivel, 3/8 nptm x

3/8 npsm 719 * STRAINER, 100 mesh screen 1 720 155541 FITTING, swivel, elbow 1

702

708

719

710

707

701

ti19059a

711

▲ Replacement Danger and Warning labels, tags and

cards are available at no cost.

* Strainer Options:

Mesh 2-pack 25-pack

30 224458 238436 60 224459 238438 100 224468 238440 200 224469 238442

3A2012J 63

System Parts

Resin Supply Hose

16M736

807

801

Ref Part Description Qty

801 220372 HOSE, coupled, 6 ft 1 802 197682 TUBE, suction 1 803 114967 COUPLING, pipe, 1 in. 1 804 195151 TUBE, intake 1 805* 20397-01 FILTER, 24 mesh, 1 in. npt 1 807 16M776 FITTING, elbow, 3/4 npsm x

1 nptf

802

803

805

804

Apply pipe sealant to all non-swiveling pipe threads.

* Other filter meshes available: 50 mesh (20397-03),

100 mesh (20397-02).

64 3A2012J

System Parts

3A2012J 65

System Parts

Catalyst Slave Pumps

910

926

902d

902b

946

935

909

907

909

919

920

921

Internal Mix shown

922

WLE

924

External Mix Only

939

908

919

925

923

947

902

901

932

1 4

947

902f

902a

902g 902f

903

903a

ti19060a

902e

911

912 913

914

940

903b

945

Apply pipe sealant to threads.

Apply thread locker to mating surfaces or threads.

Apply grease to mating surfaces or threads.

Torque to 240 in-lb (27.1 N•m).

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

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

Note orientation of u-cup.

Torque to 30-50 in-lb (3.4-5.6 N•m).

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).

Press fit bearings.

Torque piston rod (910) to top link (926) to 80-100 in-lb (9.0-11.3 N•m).

Torque to 20 - 60 in-lb (2.3-6.8 N•m).

Snap 902e onto 902a.

Orient so inside chamfer of nipple (936) is mated to swivel (930).

915

916

917

918

Series D only

903c

920

Series D

only

936

930

924

932

946

934

938

939

947

937

66 3A2012J

System Parts

Catalyst Pumps

Qty.

Ref. Part Description

901 --- HOUSING, slave pump 1 1 902 24C479 KIT, cartridge, FRP 1 1 902a --- CARTRIDGE, slave pump 1 1 902b 902d 902e

902f 902g 903 16N975 VALVE, 3000 psi blow off (also

903a 224807 BASE, valve 1 1 903b 15C780 HANDLE 1 1 903c 15C972 PIN, spring 1 1 907 113641 GAUGE, pressure, fluid 1

908 123595 PIN, quick release 1 1 909 124193 CABLE, lanyard, 5 inch 1 1 910 16N964 ROD, piston, slave pump (also

911 912 913 914 16K960 HOUSING, transfer, etched 1 1 915 916 917 16A666 CAP, transfer housing 1 1

918 16N965 CYLINDER, slave pump (also

919 920

921 LPA-144 NUT, lock 1 1 922 16N976 HOUSING, inlet, slave 1 1 923 924 --- BEARING, flanged, 0.375 ID 2 2 925 926 16N617 KIT, repair, catalyst pump yoke 1 1 930 114339 FITTING, union, swivel, 1/4 npt 1 1 932 123628 FITTING, adapter, 1/8 npt - #4

934 297085 FITTING, elbow, 0.125 in., st 1

--- BEARING, cartridge 1 1

†

--- WIPER, felt, piston rod 1 1

†

16P186 SEAL, snap on, cartridge 1 1

✿

16A981 SEAL, slave pump weep 2 2

✿

123556 O-RING, silicone #016 1 1

✿

includes 903a, 903b, and 903c)

124432 GAUGE, 160 psi 1

includes 919, 920, and tool 16D007)

123636 SPRING, transfer housing 1 1

★

16K928 VALVE, poppet 1 1

★

123934 O-RING, 003, FKM 1 1

★

LPA-126 SEAL, radial 1 1

★

LPA-127 GUIDE, piston 1 1

★

includes 919 [Qty 2] and 920 [Qty 2])

CJ-143 O-RING, o-ring, silicone, 2-014 2 2

✿‡

124061 RING, backup, 0.518 ID,

✿‡

0.053 wide

--- SEAT, ball, 7/16 dia. 1 1

‡

LPA-134-02 BALL, spherical 1 1

jic

16N740, for Internal Mix

1 1

2 2

1 1

Ref. Part Description

935 110208 PLUG, pipe, headless 1 936 94/0320-1/98 FITTING, nipple, 1/4; series D

16N741, for External Mix

937 124379 VALVE, check, npte x npti, 100

938 16V706 FITTING, tee, compression, 1/4 1 939 --- TUBE, polyethylene 0.5 940 24U857 VALVE, ball, mini; no tused on

080803 VALVE, ball, 1/4 npt, ff, 316 sst;

945 16V703 FITTING, 1/4 npt x 3/8 tube, sst 1 1 946 16V704 FITTING, 1/8 npt x 1/4 tube, 90,

947 16V705 FITTING, 1/8 npt x 1/4 tube, sst 1 2

only

psi

series D

series D only

sst

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

Qty.

16N740, for Internal Mix

1 1

16N741, for External Mix

3A2012J 67

System Parts

Catalyst Reservoir

16P425

1011

1001

1002

1010

1001

Apply pipe sealant to threads.

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

1012

For outlet strainer and filter, see Carts on page 55.

Ref Part Description Qty

1001 --- TANK, gravity feed, 2.5 gallon 1 1002 24M159 STRAINER, tank, gravity feed 1 1010 16M754 LABEL, maximum fill line 1 1011 16V704 FITTING, 1/8 npt x 1/4 tube, 90;

sst

1012 16M738 LABEL, hazardous material

diamond

68 3A2012J

System Parts

Cart not included in kit, shown for reference only

3A2012J 69

System Parts

Hose Bundles

1102

1104

1109

1105

1114

1115

1101

1108

1103

1113

1106

1111

1107

1102 (Catalyst)

1105 (External Atomizing Air/ Internal Chop AAC Air)

1101 (Chopper Air/Internal Gel AAC)

1103 (Resin)

ti21345a1

1104 (Internal Solvent/ External AAC)

70 3A2012J

System Parts

Hose Bundles

Quantity

16M584,

16M583,

50 ft,

Ref Part Description

1101* 16J767 TUBE, 3/8 in., polyethyl-

ene, 28 ft

16J768 TUBE, 3/8 in., polyethyl-

ene, 38 ft

16J769 TUBE, 3/8 in., polyethyl-

ene, 53 ft

590570 TUBE, 1/2 IN., polyethyl-

ene

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

1104 24C543 HOSE, coupled, 1/4 in.,

1105 --- TUBE, polyethylene,

1106 124427 JACKET, blue scuff 22ft 2 2 2

1107 16M606 JACKET, blue scuff 15ft 1 1 1 1108 158256 UNION, swivel 1 1 1 1109 277249 HOSE, coupled, 1/4 in. x

1110◆ 744 GUIDE, roving, hose 1 1 1 1111

1112 114271 STRAP, retaining 1 1 1 1 1 1 1113 123379 FITTING, reducer,

1114 520563 TUBE, 3/8 in., polyethyl-

1115 16U657 UNION, 1/2 in. x 3/8 in.

▲ Replacement Danger and Warning labels, tags and cards

† The 25 ft and 35 ft hose bundles come with 50 ft of resin

240797 HOSE, coupled, 3/8 x

†

50 ft

277253 HOSE, coupled, 1/2 in. x

50 ft

nylon, 28 ft

24C544 HOSE, coupled, 1/4 in.,

nylon, 53 ft

24G434 HOSE, coupled, 1/4 in.,

nylon, 40 ft

0.250 outer diameter

124428 JACKET, blue scuff 47ft 1 1 1 16M599 JACKET, blue scuff 29ft 1 1 1

3 ft, 4000 psi

16D659 LABEL, warning, hose

▲

bundle

3/8 nptx1/4 npt

162449 FITTING, nipple, reducing 1 1 1

ene

OD tubing

are available at no cost.

hose. The extra resin hose is coiled at the factory and is part of the pressure surge suppression system.

chop

53 ft 28 ft 35 ft

53 ft 53 ft 28 ft 28 ft 38 ft 38 ft

2.5 ft 2.5 ft 2.5 ft

internal

1 1 1

1 1 1 1 1 1 1 1 1

1 1 1

16M585,

50 ft

gel

1 1 1 1 1 1

50 ft

16M586,

external

gel

* Series C and prior chop hoses use 16J769. Series D or

◆ Not shown.

25 ft,

chop

later chop hoses are shown in the table.

16M587,

internal

1 1 1

25 ft,

gel

16M588,

25 ft,

external

gel

16M590,

16M589,

35 ft, chop

35 ft,

internal

gel

1 1 1

16M591,

35 ft,

external

gel

3A2012J 71

System Parts

Accessory Parts

Heater Kits

1202b

1202a

1202f

1202e

1202d

16N014 and 16N015 Kits

1206

1205

1214

1213

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.

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

1204

1201

1202d

1202c

1215

1210

1211

1204

1203

1210

ti21346a

1213

1202b

1202a

1202f

1202e

1202d

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

1202a

1203

1204

1202d

1202c

1213

1211

1215

1208

ti21347a

1213

1214

1210

72 3A2012J

System Parts

Heater Kits

Quantity

16N014,

120v, FM

Ref Part Description

1201* 16N013 BRACKET, heater 1 1 1 1 1 1 1202* 16P291 KIT, pipe clamp 2 2 2 2 2 2 1202a† 19891-00 CLAMP, pipe, set 1 1 1 1 1 1 1202b† 19892-00 PLATE, cover, clamp 1 1 1 1 1 1 1202c† 115211 SCREW, cap, hex hd 2 2 2 2 2 2 1202d† 113962 WASHER, hardened 4 4 4 4 4 4 1202e† 100018 WASHER, lock, spring 2 2 2 2 2 2 1202f† 100321 NUT 2 2 2 2 2 2 1203* 100058 SCREW, cap, hex head 4 4 4 4 4 4 1204* 110755 WASHER, plain 8 8 8 8 8 8 1205* 100131 WASHER, lock 4 4 4 4 4 4 1206* 100015 NUT, hex, mscr 4 4 4 4 4 4 1208* 162449 NIPPLE, reducing 1 1 1 1 1 1 1209* 159239 NIPPLE, pipe, reducing 1 1 1 1 1 1 1210* 158491 NIPPLE 2 2 2 2 2 2 1211* H55003 HOSE, coupled, 5600

psi 1212* --- TAPE, PTFE 1 1 1 1 1 1 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 1

245863 HEATER, viscon HP 1 245867 HEATER, viscon HP 1 245869 HEATER, viscon HP 1 226819 HEATER, viscon, 240

volt

226816 HEATER, viscon, 120

volt

★

111111

222222

111111

16N015,

240v, FM

★

16N016,

120v,

hazardous

16N017,

240v,

hazardous

16N018, 120v, nonhazardous

16N019, 240v, nonhazardous

* Items are available in heater hardware kit 16N119.

† Parts available in pipe clamp kit 16P291.

★ Heaters can be disassembled to remove cured material.

3A2012J 73

System Parts

Solvent Pressure Pot Kits

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

1307

1306

1310

1309

1303

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.

1311

1304

1305

1302

1301

Ref Part Description Qty

1301 20324-00 TANK, solvent, 2 gallon

(assembly 16M893 only)

20324-01 TANK, solvent, 5 gallon

(assembly 16M894 only) 1302 16D939 FITTING, nipple, reducing 1 1303 11021-23 PLUG, pipe, 1/4 1 1304 18470-05 VALVE, ball, 2-way, 1/4nptf 1 1305 RM-856-04 FITTING, elbow, 1/4 nptm x

1/4 nptm 1306 20655-04 FITTING, elbow, 3/8 nptm x

3/8 tube 1307 103347 VALVE, safety, 100 psi 1 1308 21035-00 STRAINER, pick-up, material 1 1309 21462-01 FITTING, adapter, 1/4 nptm x

3/8 nptf 1310 3165 VALVE, ball, 2-way,

3/8 female, 3/8 male 1311 17440-00 CLAMP, grounding 1

74 3A2012J

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

1411

1406

1410

1408

1412

1401

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.

1404

1401

1414

1403

1402

1408

1405

1409

1406

System Parts

Ref Part Description Qty

1401 236086 TANK, pressure assy, 2 gal.

(assembly 16M874 only)

236087 TANK, pressure assy, 5 gal.

(assembly 16M875 only) 1402 165053 PACKING, o-ring 1 1403 188880 PLUG, lid 1 1404 188784 NUT, jam, hex 1 1405 171976 TUBE

(assembly 16M875 only)

185531 TUBE, siphon (assembly

16M874 only) 1406 --- BUSHING, hex, 3/8npt x 1/4npt,

male/female 1407 111763 FITTING, elbow, 1/4 npt 1 1408 18470-05 VALVE, ball, 2-way, 1/4nptf 2 1409 --- FITTING, nipple, reducing 1 1410 108673 TEE, street 1 1411 103347 VALVE, safety, 100 psi 1 1412 --- FITTING, connector, male,

3/8 npt 1413 210575 CAP, filler (assembly 16M875

only, not shown) 1414 176347 LABEL, identification 1

1401

Ref Part Description Qty

1415 --- LABEL, designation 1 1416▲ 175078 LABEL, warning 1

1421 308370 MANUAL 1 1423 17440-00 CLAMP, grounding 1

1424 171988 O-RING (for filler cap,

item 1413, not shown)

▲ Replacement Danger and Warning labels, tags and

cards are available at no cost.

3A2012J 75

System Parts

Solvent Diaphragm Pumps

2-gallon 16M560 and 5-gallon 16M561

1505

1502,1503

1504

1501,1503

Base System shown for reference only

Ref Part Description Qty

1501 16M559 PUMP, solvent, FRP, flush 1 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 1 1504 --- TUBING, nylon, round 3 1505 16N891 KIT, pick-up tube, 2.5 gallon

(16M560 only)

16N892 KIT, pick-up tube, 5 gallon

(16M561 only)

76 3A2012J

DataTrak Upgrade Kit

16M881

System Parts

1602

Ref Part Description Qty

1601 * 24A354 SMART AIR VALVE (not shown) 1 1602 24A576 DATATRAK CONVERSION KIT 1

* See FRP air motor manual.

3A2012J 77

System Parts

Carts for 55 Gallon Barrel, 16M896

1717

1706

1705

1718

1704

1716

1711

1714

1715

1713

Ref Part Description Qty

1701 --- PLATE, 55 gal drum 1 1702 16P134 CASTER, rigid 2 1703 16M465 CASTER, locking 2 1704 113962 WASHER, hardened, sae 6 1705 100321 NUT 4 1706 16N977 BRACKET, drum cart 2 1707 100521 SCREW, cap hex head 8 1708 100023 WASHER, flat 16 1709 104008 WASHER, lock, spring 8 1710 GC2096 NUT, hex, standard, 5/16-18 8 1711 16N978 BRACKET, handle, drum cart 1 1712 100424 SCREW, cap, hex head 2 1713 116645 SCREW, cap, hex head 1 1714 100696 WASHER, wrought 1 1715 100052 WASHER, lock 1 1716 124291 PIN, spring 1 1717 258982 HANDLE, cart 1 1718 100018 WASHER, lock, spring 4

1703

1708

1709

1710

1702

1712

1704, 1705, 1718

1701

WLE

1707 1708

--- Not for sale.

78 3A2012J

Roving Box Bracket

16M961

1802

1801

1803

System Parts

ti18525b

1807†

1804,1805

1806

Ref Part Description Qty

1801 16M619 BRACKET, roving 1 1802 16M622 BRACE, roving box 1 1803 122741 SCREW, hex cap, 1/4 x 0.50 2 1804 104123 WASHER, lock, spring 2 1805 112248 NUT, hex 2 1806 16M965 CLAMP, u-bolt 2 1807† 15J889 SCREW, hex 2

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

side by side.

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

3A2012J 79

System Parts

Extension Hoses

Gel Hose

1906

1904

1905

1901

1907 1903

Chop Hose

1913

1906

1902

1904

1905

1907 1903

1903, 1907 (Resin)

1913

1904, 1912 (Internal Solvent/ External AAC Air)

1902

ti21348a

1902, 1909 (Catalyst)

1905, 1911 (External Atomizing Air/ Internal Chop AAC Air)

1901, 1910 (Chopper Air/ Internal Gel AAC)

Quantity

Ref Part Description

16M712,

for chop systems

16M718,

for internal gel

16M719,

for external gel

1901 16J766 TUBE, 3/8 in. polyethylene, 25 ft 1

590570 TUBE, 1/2 in. polyethylene 25.5 ft

1902 24J730 HOSE, coupled, 1/8 in., 3000 psi,

1 1 1

25 ft

1903 240796 HOSE, coupled, 3/8 x 25' 1 1

16M731 HOSE, coupled, 1/2 in. x 25',

4000 psi

1904 24J731 HOSE, coupled, 1/4 in., nylon,

1 1 1

25 ft 1905 --- TUBE, polyethylene, 1/4 in. OD 25 ft 25 ft 1906 124427 JACKET, blue scuff, 22 ft 1 1 1 1907 158256 UNION, swivel 1 1908 744 GUIDE, roving, hose (not shown) 1 1909 123553 FITTING, nipple, #4 JIC 1 1 1 1910* 123554 COUPLER, 3/8 in. OD tubing 1

16U953 COUPLER, 1/2 in. OD tubing 1 1911 123789 COUPLER, 1/4 in. OD tubing 1 1 1912 123552 FITTING, nipple, 1/8 npt 1 1 1 1913▲ 16D659 LABEL, warning, hose bundle 1 1 1

▲ Replacement Danger and Warning labels, tags and

cards are available at no cost.

80 3A2012J

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

Dimensions

Cart and Boom

Dimensions

Ref.

(Max Width)

(Max Height)

(Max Depth)

¡

ti18526b

Top View

(Radius)

¡

(Radius)

Description

* Rotate unit to fits cart and boom system through a 3 ft 6 in. wide door, with a 9 in. jamb width.

** Height with boom installed. Height of unit without the boom is 83 in. (2108 mm).

3A2012J 81

144 in.

(3658 mm)

100 in.

(2540 mm)

192 in.

(4877 mm)

144 in.

(3658 mm)

72 in.

(1828 mm)

Dimensions

Cart Only

Ref. Cart Only

Wall/Pole Mount

(Max Width)

(Max Height)

(Max Depth)

ti18496b

29.5 in.

(749 mm)

47.75 in.

(1213 mm)

32.5 in.

(826 mm)

ti18524d

Ref. Wall/Pole Mount

(Max Width)

(Max Height)

(Max Depth)

39.0 in.

(991 mm)

46.6 in.

(1183 mm)

32 in.

(813 mm)

82 3A2012J

Pumpline Wall Mounting Bracket Dimensions

The pumpline bolts directly to this mounting plate.

3.52 in.

(89.4 mm)

WLD

10.1 in.

(257 mm)

Four 0.60 in. (15 mm) mounting holes

Technical Data

System Technical Data

Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . 13:1 Systems: 1300 psi (9 MPa, 90 bar)

17:1 Systems: 1700 psi (11.9 MPa, 119 bar)

Maximum air inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7.0 bar)

Maximum air inlet pressure to ASME solvent pressure pots . . . 100 psi (0.7 MPa, 7.0 bar)

Typical flow rate of pattern guns . . . . . . . . . . . . . . . . . . . . . . . . Refer to RS Gun manual. See Related Manuals, page 3.

Maximum fluid temperature (Models with RS Gun) . . . . . . . . . . 100°F (38°C)*

Maximum fluid temperature (Models without RS Gun) . . . . . . . 160°F (71°C)*

A component (catalyst) inlet size . . . . . . . . . . . . . . . . . . . . . . . . 3/8 in. tube

B component (resin) inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5/16-12 UN-2A male

Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless steel, carbide, UHMWPE, PTFE, and acetal.

Resin wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Pumpline Technical Data, page 84

Catalyst wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Catalyst Pump Technical Data, page 84

* Maximum fluid temperature rating determined by

lowest rated component in system.

3A2012J 83

Technical Data

Pumpline Technical Data

Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . 13:1 Systems: 1300 psi (9 MPa, 90 bar)

17:1 Systems: 1700 psi (11.9 MPa, 119 bar)

Maximum air inlet pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7.0 bar)

Minimum air inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 psi (0.07 MPa, 0.7 bar)

Maximum ambient air temperature. . . . . . . . . . . . . . . . . . . . . . . 120°F (49°C)

Maximum cycle rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 cpm

Air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Technical Data in air motor manual 3A2315.

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

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

Maximum fluid temperature 160°F (71°C)

NOTE: System rating is lower than this due to other, lower-rated

components.

Stroke length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 in. (51 mm)

Sound data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Technical Data in air motor manual 3A2315.

Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless steel, tungsten carbide with 6% nickel,

UHMWPE, PTFE,

LW100C displacement pump only: Also includes carbon steel

Catalyst Pump Technical Data

Maximum fluid working pressure

Internal catalyst pump version. . . . . . . . . . . . . . . . . . . . . . . 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 stain-

less 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.

84 3A2012J

Technical Data

3A2012J 85

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissen 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.

t avoir convenu que la

Graco Information

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

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

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

Original instructions.

This manual contains English. MM 3A2012

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised June 2014

Graco ti18496b, ti18526c, ti18524d User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Agency Approvals

Models

Accessories

Warnings

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information

Important Two-Component Material Information

Material Self-ignition

Changing Materials

Keep Resin and Catalyst Components Separate

Overview

Component Identification

Air Control Panel

Air Motor and Resin Displacement Pump

Catalyst Pump

Solvent Flush Systems

Setup

Before Installation

System Mounting (Wall Mount Systems Only)

Location Requirements

System Assembly

Grounding

Connect Fluid and Air Lines

Flush Before First Use

Fill Supply Tanks

Operation

Trigger Lock

Boom Operation

Pressure Relief Procedure and Shutdown

Startup

Prime

Flush

Spray

DataTrak Operation

Replace DataTrak Battery or Fuse

Maintenance

Components

Troubleshooting

Catalyst Pump

Resin Pump

Repair

General Information

Disconnect the Displacement Pump

Reconnect the Displacement Pump

Disconnect the Air Motor

Reconnect the Air Motor

Replace Pumpline

Repair Catalyst Pump

System Parts

Systems

Carts

Wall or Pole Mount Kit, 16N918

Boom, 16N761

Air Panel

Slave Pump Linkage, 16P125

Resin Pumplines

Air Motor and Pump for Resin Pumpline

Resin Filter

Resin Supply Hose

Catalyst Slave Pumps

Catalyst Reservoir

Hose Bundles

Hose Bundles

Accessory Parts

Heater Kits

Solvent Pressure Pot Kits

Solvent Diaphragm Pumps

DataTrak Upgrade Kit

Carts for 55 Gallon Barrel, 16M896

Roving Box Bracket

Extension Hoses

Dimensions

Cart and Boom

Cart Only

Wall/Pole Mount

Pumpline Wall Mounting Bracket Dimensions