Graco 3A2012J Frp Proportioner Users Manual Proportioner, Instructions Parts, English

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3A2012J

Instructions - Parts

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.

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.

Important Safety Instructions

Read all warnings and instructions in this manual and

all component manuals. Save all instructions.

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.

Wall Mount SystemCart and Boom System Cart System

ti18526c

ti18524d ti18496b

EN

II 2 Gc T5

23A2012J

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

Related Manuals

3A2012J 3

Related Manuals

Manuals are available at www.graco.com. Component

manuals in English:

Agency Approvals

* Solvent pots do not affect Atex rating.

Manual Description

3A0232 RS

™

Gun Instructions-Parts

3A2313 U-Cup Displacement Pump

3A2315 NXT

®

Air Motor for FRP

332451 FRP Stainless Steel Fitting Kit

308981 Air Operated Diaphragm Pumps

309524 Viscon HP Heater Instructions

307363 Viscon

®

Heater Instructions

313541 DataTrak

™

Conversion Kit Instructions

308370

ASME and CE-Approved Pressure Pot

Instructions (Solvent Flush Pressure Pot)

307273 Fluid Outlet Filter

407019 Chop Cart Legs Kit

407020 55 Gallon Drum Kit

407021 Roving Box Bracket Kit

407022 Deluxe Inlet Seat Removal Tool

407023 5 Gallon Catalyst Reservoir Kit

407024 Boom Kit

407025 DataTrak

™

Upgrade Kit

407026 Wall or Pole Mount Kit

407027 Linkage Replacement Kit

407028 Resin Pump Connecting Kit

407031 Diaphragm Pump Solvent Flush Kit

407032

Non-CE Approved Solvent Pressure Pot

Kits

407033

ASME and CE-Approved Pressure Pot

Kits

407042 Heater Kits

Manual Description

FRP proportioner systems are approved for use in

hazardous locations when the base model, all acces-

sories, and all kits meet all wiring meet local, state,

and national codes.

Base FRP System with no accessories*

Accessories See accessory manuals listed in Related Manu-

als section for approvals.

II 2 Gc T5

Models

43A2012J

Models

Ratio

Internal or

External

Mix

Gel or

Chop

No Cart Cart Cart, Mast, and Boom

Part No.

Hose

Length

ft (m) Part No.

Hose

Length

ft (m) Part No.

Hose

Length

ft (m)

13:1

Internal Mix

Gel

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 ---

Chop

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 ---

External

Mix

Gel

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 ---

Chop

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 ---

17:1

Internal Mix Gel

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 ---

External

Mix Gel

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 ---

Accessories

3A2012J 5

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.

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.

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 2 Gallon, ASME and CE-approved, Solvent

Flush Pressure Pot

16M875 5 Gallon, ASME and CE-approved, Solvent

Flush Pressure Pot

16M893 2 Gallon, ASME Solvent Flush Pressure Pot

16M894 5 Gallon, ASME Solvent Flush Pressure Pot

Heaters

Part Description

16N014★120V Viscon Heater, for hazardous loca-

tions

16N015★240V Viscon Heater, for hazardous loca-

tions

16N016 120V Viscon Heater, for hazardous loca-

tions and explosive atmospheres

16N017 240V Viscon Heater, for hazardous loca-

tions and explosive atmospheres

16N018 120V Viscon Heater, for non-hazardous

locations

16N019 240V Viscon Heater, for non-hazardous

locations

★Heaters can be disassembled to remove

cured material.

Extension Hoses

Part Description

16M712 25 ft Extension Hose Bundle for Chop Sys-

tems

16M718 25 ft Extension Hose Bundle for Internal Gel

Systems

16M719 25 ft Extension Hose Bundle for External

Gel Systems

55 Gallon Barrel Carts

Part Description

16M896 55 Gallon Barrel Cart

Roving Box Bracket

Part Description

16M961 Roving Box Bracket Kit

DataTrak Upgrade

Part Description

16M881 DataTrak Upgrade Kit

5 Gallon Catalyst Reservoir

Part Description

24M501 5 Gallon Catalyst Reservoir Kit

Wall Mounting

Part Description

16N918 FRP Pole or Wall Mount Kit

Pump Connecting Kits

Part Description

16N242 17:1 Pump Connecting Kit

16N243 13:1 Pump Connecting Kit

Warnings

63A2012J

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion 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.

Warnings

3A2012J 7

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.

WARNING

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information

83A2012J

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 pro-

duces the hazards which require great care and caution in its storage, transportation, handling, processing and dis-

posal.

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 dis-

posal 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 accor-

dance 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.

Important Two-Component Material Information

3A2012J 9

Polyester Resins and Gel-Coats Spraying and Lamination Operations

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

Keep Resin and Catalyst

Components Separate

Changing Materials

• When changing materials, flush the equipment mul-

tiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical

compatibility.

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 mate-

rial 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 sand-

ings, 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 manu-

facture’s warnings and material MSDS to know spe-

cific hazards and precautions. (Graco recommends

that clean-up solvents be nonflammable.)

Some materials may become self-igniting if applied

too thickly. Read material manufacturer’s warnings

and material MSDS.

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.

Overview

10 3A2012J

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 mate-

rial 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 acces-

sories, and all kits meet all wiring meet local, state,

and national codes.

Component Identification

3A2012J 11

Component Identification

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)

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)

* Internal mix systems only.

WLF

Cart system shown with solvent

flush diaphragm pump and exter-

nal mix gel gun

A

B

C

D

E

F

H

L

M

N

Component Identification

12 3A2012J

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.

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 pres-

sure.

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.

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

F

IG

. 1: Air Control Panel Components

AD

AC AM

AH

AK

AF

AP

AE

ABAG

FRONT REAR

AN

ti21338a ti21339a

AA

Air Outlet Fitting

Details

Internal Chop External Chop Internal Gel External Gel

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

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

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

Component Identification

3A2012J 13

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.

Fluid inlet (S): connect fluid suction hose to the

3/4 npt(m) fluid inlet.

DataTrak (T) (optional): electronic monitoring for mate-

rial tracking, system diagnostics, and pump runaway

control. The DataTrak is located on the air control panel.

See the NXT Air Motor manual for details of the Data-

Trak controls and indicators.

F

IG

. 2

S

R

N

M

P

P1

ti18499c

Component Identification

14 3A2012J

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 pres-

sure.

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.

F

IG

. 3: Catalyst Pump Components

V1

X

U

W

Z2

Z

Z3

YV2

U

ti21340a

Z1

Z2

Z

ti21342a

Z3

Y2

Component Identification

3A2012J 15

Solvent Flush Systems

Solvent Flush Diaphragm Pump

The solvent flush diaphragm pump provides solvent to

the gun to clear out mixed fluid and prevent it from cur-

ing in the gun. See the diaphragm pump manual listed

on page 3 for detailed component identification.

Solvent Flush ASME Pressure Pot

The pressure pot works by using the incoming air pres-

sure to expel the solvent in the pot out of the fluid outlet.

Verify supply tube is installed on fluid outlet port.

Solvent Flush ASME and CE-Approved Pressure Pot

The pressure pot works by using the incoming air pres-

sure 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.

F

IG

. 4: Solvent Pump Components

3/4 npt(f) Fluid

Outlet

3/4 npt(f)

Fluid Outlet

3/4 npt(f) Fluid Outlet

1/4 npt(f)

Air Inlet

ti9078a1

Air Inlet Fill Cap Fluid Outlet

ti18530a

Air Inlet Fill Cap Fluid Outlet

ti18531a

Setup

16 3A2012J

Setup

FRP proportioners are not approved for use in hazard-

ous locations unless all accessories, all kits, and all wir-

ing meet local, state, and national codes. See Agency

Approvals on page 3.

This section provides instructions for basic system setup

of the FRP proportioner. See the separate component

manuals for detailed information.

Before Installation

•Have all system and component documentation

available during installation.

•See component manuals for specific data on 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. Acces-

sories are available from Graco.

Component identification illustrations are only a guide

for selecting and installing system components and

accessories. Contact your Graco distributor for assis-

tance in designing a system to suit your particular

needs.

Location Requirements

Refer to Dimensions, page 81, for mounting and clear-

ance dimensions.

Cart Mount Systems

• Position the FRP proportioner so the air controls

and catalyst ratio adjustment arm are easily acces-

sible.

• If using a cart and boom system, ensure there is

enough space overhead and surrounding the pro-

portioner for the boom and mast to fully extend.

• Place on a flat and level surface.

System Mounting (Wall Mount

Systems Only)

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 cata-

lyst pump to enable gravity feed. Be sure the bracket is

level.

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.

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.

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.

NOTICE

To prevent damage to the system caused by the sys-

tem falling off the wall, be sure the wall can support

the weight of the pump, bracket, hoses and accesso-

ries, and stress caused during pump operation.

ti18527d

Setup

3A2012J 17

NOTE: Catalyst reservoir outlet must be above the cata-

lyst 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.

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

lyst reservoir onto the catalyst reservoir mount-

ing bracket.

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

pumpline mounting bracket to wall.

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

pumpline to pumpline mounting bracket.

Setup

18 3A2012J

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.

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

remove the pallet, then place item directly on

the floor.

2. Connect heater (if ordered):

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.

b. Connect heater electrical connections. See

heater manual listed on page 3 for detailed

instructions.

ti18523c

• 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 com-

ply with local electrical codes for hazardous areas.

• Wiring, wiring connections, switches, and electrical

distribution panel must all meet flame-proof (explo-

sion-proof) requirements.

Viscon Heater Shown

ti18529b

Setup

3A2012J 19

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.

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).

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.

Solvent Flush Dia-

phragm Pump shown

ti18455c

ti18532b

Spring

Chain

Deflector Plates

Roving Guides

ti18525b

Setup

20 3A2012J

Grounding

General Grounding Guidelines

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

ground clamp to a true earth ground.

Air and fluid hoses: use only electrically conductive

hoses.

Spray gun: ground through connection to a properly

grounded fluid hose and pump.

Fluid supply container: follow local code.

Object being sprayed: follow local code.

Solvent pails used when flushing: follow local code.

Use only conductive metal pails, placed on a grounded

surface. Do not place the pail on a nonconductive sur-

face, such as paper or cardboard, which interrupts

grounding continuity.

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 tight-

ened securely to the air motor. Connect the other

end of the ground wire to a true earth ground.

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 dia-

phragm pump manual listed on page 3 for

grounding details.

b. Connect the other end of the grounding clamp

to the cart.

3. Use an ohmmeter to verify all components are

grounded to the earth ground.

4. If wall power is used to power the heater, ground

electrical connection according to local codes.

5. For cart proportioners: Connect the other end of the

second supplied grounding clamp to the cart.

For wall proportioners: Connect the other end of the

second supplied grounding clamp to a true earth

ground.

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

F

IG

. 5: Ground Wire

ti18454a

Ground

screw

Grounding

wire

Setup

3A2012J 21

Connect Fluid and Air Lines

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 bun-

dle is the end with more flexible lines. See gun manual

for hose bundle connection details and individual hose

identification.

Air Connections

1. Verify air line from air outlet 1 (AC) on air control

panel is connected to air inlet (M) on air motor. See

F

IG

. 2 on page 13 and F

IG

. 7.

2. Connect AAC air line from gun hose bundle to air

outlet 3 (AM) on air control panel. See gun manual

for AAC air line identification.

3. External mix proportioners only: Connect the sup-

plied air tubing attached to air outlet 2 (AF) to atom-

ized air line on gun.

Internal mix proportioners only: Connect the sup-

plied air tubing attached to air outlet 2 (AF) to sol-

vent pump air inlet. See F

IG

. 4 on page 15.

4. Chop systems only: Remove plug then connect the

chop air line (0.375 in. tube) in the gun hose bundle

to the chop air fitting (AN) on the air control panel.

5. Verify air shutoff valve (AP) is closed (handle is ver-

tical) then connect the air supply line to the air

inlet (AA) on the air control panel.

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

Oil left in the system at the factory can react with cata-

lyst and create a fire or explosion.

• Flush before first use.

• Do not add catalyst to the catalyst reservoir until

the system has been flushed.

F

IG

. 6: Hose End Diagram

Solvent/ AAC Air

Catalyst

External Atomizing/

Internal Chop AAC Air

Resin (Whip

Hose)

Air (Chop/

Internal Gel

AAC)

F

IG

. 7: Air Control Panel Components

Air Outlet Fitting

Details

Internal Chop External Chop Internal Gel External Gel

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

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

Air Outlet 4 (AN)

★

1/2 tube 1/2 tube Plugged Plugged

AD

AC AM

AH

AK

AF

AP

AE

ABAG

FRONT REAR

AN

ti21338a ti21339a

AA

Setup

22 3A2012J

Resin Pump and Optional Heater Connections

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.

Catalyst Pump Fluid Connections

NOTE: See F

IG

. 3 on page 14.

11. Verify the pressure relief/recirculation valve (W) is

set to pressure relief (knob is horizontal).

12. Connect the catalyst line from the gun hose bundle

to the catalyst outlet (Z1).

F

IG

. 8

S

R

N

M

P

P1

ti18499c

F

IG

. 9: Catalyst Pump Pressure Relief Valve

W

ti21343a

Setup

3A2012J 23

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 dia-

phragm 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 sol-

vent 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 sup-

port located on the pole. Secure with the supplied

rubber straps. The hook support should be inserted

through the center of the hose coil.

17. Secure all connections on the whip-end of the hose

bundle to the gun. See the gun manual listed on

page 3 for detailed instructions.

Flush Before First Use

Flush the system before first use to prevent contaminat-

ing the resin or catalyst. See page 30.

Fill Supply Tanks

Add fluid to the solvent flush supply tank (if applicable),

the catalyst supply reservoir, and the resin supply con-

tainer.

Oil left in the system at the factory can react with cata-

lyst and create a fire or explosion.

• Flush before first use.

• Do not add catalyst to the catalyst reservoir until

the system has been flushed.

Operation

24 3A2012J

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

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

1. Close the main air supply ball valve.

2. Turn the main air supply pressure regulator fully

counter-clockwise.

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

IG

. 11.

4. With a grounded bucket below the gun, press the

gun against the side of the bucket and pull the trig-

ger to relieve pressure in the fluid lines.

ti18532b

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 Proce-

dure when you stop spraying and before cleaning,

checking or servicing the equipment.

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.

F

IG

. 10

F

IG

. 11

Operation

3A2012J 25

5. Engage trigger lock.

6. Turn catalyst pump pressure relief/recirculation

valve to the pressure relief position.

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.

8. After the pressure is fully relieved, turn the pressure

relief/recirculation valve to dispense position.

9. If you suspect the spray tip, hose, or filter is com-

pletely clogged or that pressure has not been fully

relieved after following the previous steps, very

slowly loosen the hose end coupling and relieve

pressure gradually; then loosen completely.

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

and maintenance procedures.

11. Perform the scheduled maintenance items listed on

page 38.

F

IG

. 12

F

IG

. 13

F

IG

. 14

F

IG

. 15

Operation

26 3A2012J

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.

1. Verify wetcup is filled with Graco Throat Seal

Liquid (TSL

™

).

2. Ensure main air line is connected to the air control

panel air inlet (AA).

3. For internal mix proportioners only, check solvent

line:

a. Verify gun is ready to begin operation. See gun

manual.

b. Turn shutoff valve (AP) on the air control panel

to the open position.

c. Open the air valve on the solvent pump and

adjust the solvent pressure to 90 psi (0.63 MPa,

6.3 bar).

d. Open the ball valve on the solvent pump.

e. Open solvent knob on the gun to verify that sol-

vent will flow out of the front of the gun through

the dispense tip, then close the valve.

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

Flush procedure on page 30.

5. As desired, perform Prime, Flush, or Spray proce-

dures beginning on page 27. Make sure to flush the

system before first use to flush out oil used to test

the equipment at the factory.

To avoid overpressurization, before turning on the

main air supply ensure all regulators are adjusted fully

counter-clockwise so they are set to zero pressure.

Oil left in the system at the factory can react with cata-

lyst and create a fire or explosion.

• Flush before first use.

• Do not add catalyst to the catalyst reservoir until

the system has been flushed.

Operation

3A2012J 27

Prime

Perform this procedure upon initial system setup, when-

ever hoses are disconnected, if the supply hose is

removed from the supply container, or if either pump is

run dry. If done properly, this will prime the lines with

fluid and/or remove any air bubbles from the fluid lines.

NOTE: If using an NXT air motor with DataTrak, see

DataTrak Operation, page 33.

NOTE: For systems with DataTrak: When priming

pumps, it is normal to get cavitation or pump runaway

alarms. Clear alarms , and press again as

necessary. These alarms prevent excessive pump

speeds, which will damage pump packings.

1. To enable the user to better see fluid exiting each

fluid port, the front end of the RS gun can be

removed. This step is optional but can be very use-

ful:

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.

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.

3. Units with runaway protection only: enable the

prime/flush function by pushing the prime/flush but-

ton 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/recircula-

tion position.

Oil left in the system at the factory can react with cata-

lyst and create a fire or explosion.

• Flush before first use.

• Do not add catalyst to the catalyst reservoir until

the system has been flushed.

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 overpres-

surization and equipment rupture. If your pump accel-

erates 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.

F

IG

. 16

Operation

28 3A2012J

5. Verify the pressure relief/recirculation valves on the

resin pump is set to the pressure relief/recirculation

position.

6. Turn the main air supply pressure regulator fully

counter-clockwise to relieve pressure and set to

zero pressure. See F

IG

. 18.

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

tion. See F

IG

. 18.

8. Slowly turn the main air supply pressure regulator

clockwise until the pump starts to move and will

change-over by itself. Never turn past 20 psi

(0.14 MPa, 1.4 bar). See F

IG

. 18.

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.

10. Turn the catalyst pump pressure relief/recirculation

valve to the dispense position.

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

IG

. 21.

12. Purge air from resin and catalyst hoses: with a

grounded bucket below the gun, press the gun

against the side of the bucket and pull the trigger to

dispense. Continue dispensing until air-free fluid is

dispensed from both ports on the front of the gun.

See F

IG

. 21. The pump air pressure may need to

increase slightly until the material begins to flow.

F

IG

. 17

F

IG

. 18

F

IG

. 19

F

IG

. 20

To reduce the risk of exposure to the dispensed mate-

rial mist, when performing the following step use a pail

lid with a hole to dispense through. Seal around hole

and gun with a rag to prevent splash back.

To reduce the risk of skin injection, be careful to keep

fingers away from front of gun.

To reduce the risk of fire and explosion, use a

grounded pail.

F

IG

. 21

Operation

3A2012J 29

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

position.

14. Turn the catalyst pump pressure relief/recirculation

valve to the pressure relief position. This will relieve

any built up pressure.

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.

16. Units with runaway protection only: disable the

prime/flush function by pushing the prime/flush but-

ton 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 mate-

rial from curing or sticking to it, then install gun front

end.

F

IG

. 22

F

IG

. 23

F

IG

. 24

Operation

30 3A2012J

Flush

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 recircula-

tion lines from the resin supply container and insert

in a container filled with a compatible solvent.

3. With the fluid lines in the two separate solvent con-

tainers, perform the Prime procedure at the lowest

pressure possible. While performing this procedure,

leave the fluid supply, recirculation, and supply lines

in the solvent containers.

Oil left in the system at the factory can react with cata-

lyst 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 injec-

tion injury, only use a solvent compatible with the sys-

tem wetted parts, the resin, and the catalyst.

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.

Operation

3A2012J 31

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 over-

night. After performing this full procedure, spraying can

be performed intermittently as desired by simply pulling

the trigger and utilizing the trigger lock to prevent acci-

dental 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.

5. Turn the catalyst pump pressure relief/recirculation

valve to the dispense position. See F

IG

. 27.

6. Bring catalyst pump fluid outlet line to dispensing

pressure (see F

IG

. 27):

a. Remove pin connecting upper catalyst pump

arm to air motor rod then manually stroke the

pump until the catalyst pressure gauge shows:

External mix systems: 30-40 psi

(0.21-0.28 MPa, 2.1-2.8 bar).

Internal mix systems: 300-400 psi (2.1-2.8 MPa,

21-28 bar).

b. Insert pin to connect upper catalyst pump arm

to air motor.

F

IG

. 25

F

IG

. 26

F

IG

. 27

Operation

32 3A2012J

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

tion. See F

IG

. 28.

8. Slowly turn the main air supply pressure regulator

clockwise until the main air supply pressure gauge

reads the desired pressure. See F

IG

. 28.

9. Disengage trigger lock on the gun. See F

IG

. 29.

10. Pull trigger to begin dispensing. See F

IG

. 29.

NOTE: In the following step, to minimize catalyst over-

spray, 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 sys-

tem or gun, and adjusting the catalyst atomization

air.

12. After all pressure adjustments are made, spray a

final test shot on a clean piece of paper. This shot

should be approximately 5 ft long. Check desired

gel times and uniformity of curing.

13. For internal mix proportioners only: When finished

spraying engage trigger lock then point the gun into

a waste container and use the solvent knob on the

gun to move solvent through the gun to flush the

gun.

14. For external mix proportioners only: When finished

spraying, squirt the tip of the gun with solvent to

remove any mixed material.

15. If necessary, use a brush to remove cured material

from front of the gun.

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

Follow Pressure Relief Procedure and Shutdown

on page 24.

F

IG

. 28

F

IG

. 29

F

IG

. 30: AAC Air Adjustment

no air too little air correct amount

of air

Operation

3A2012J 33

DataTrak Operation

For DataTrak installation instructions, see NXT Air

motor for FRP manual.

Controls and Indicators

NOTE: See F

IG

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

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

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

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)

NOTICE

To prevent damage to the soft key buttons, do not

press the buttons with sharp objects such as pens,

plastic cards, or fingernails.

F

IG

. 31. DataTrak Controls and Indicators

TI11883a

CD

CF; See Details at right.

CF

BT

GT

CC

RT

CA

PF

RK

*CB

UT

DT

ST

Run Mode

Setup Mode

TI8622b

TI8623b

RK PF

/min,

Operation

34 3A2012J

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

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

Operation

3A2012J 35

Setup Mode

1. See F

IG

. 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.

NOTE: When runaway, E1, E2, and E5 error options are

enabled, a ✓ will appear on the setup screen. See F

IG

.

31.

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

then press once more to exit Setup mode.

Run Mode

Runaway Monitor

1. See F

IG

. 31. If pump runaway occurs, the runaway

solenoid will actuate, stopping the pump. The LED

(CD) will flash and the display (CF) will indicate a

runaway condition (see Table 1). The display will

cycle through six instruction screens.

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

solenoid, close the master air valve (AP). Wait for

air to completely bleed off the air motor.

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

IG

. 31).

AP F

IG

. 32. Solenoid Release Button

J

ti11902a

Operation

36 3A2012J

Prime/Flush

1. See F

IG

. 31. To enter Prime/Flush mode, press any

key to wake up the display, then press . The

Prime/Flush symbol will appear in the display and

the LED will flash .

2. While in Prime/Flush mode, runaway protection is

disabled and the batch totalizer (BT) will not count.

The grand totalizer (GT) continues to count.

1. To exit Prime/Flush mode, press any key to wake

up the display, then press . The Prime/Flush

symbol will disappear from the display and the LED

will stop flashing.

Counter/Totalizer

See F

IG

. 31. The last digit of the batch totalizer (BT) rep-

resents tenths of gallons or liters. To reset the totalizer,

press any key to wake up the display, then press and

hold for 3 seconds.

• If AC is set to gallons or ounces, BT and GT dis-

play gallons.

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

liters.

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

Press to toggle between flow rate units and cycles.

A letter under the BT display indicates that both BT and

GT are displaying gallons (g) or liters (l). No letter

means both BT and GT are displaying cycles.

Display

See F

IG

. 31. The display (CF) will turn off after 1 minute

of inactivity in Run mode or 3 minutes in Setup mode.

Press any key to wake up the display.

NOTE: DataTrak will continue to count cycles when dis-

play is off.

NOTE: The display (CF) may turn off if a high-level

static discharge is applied to the DataTrak. Press any

key to wake up the display.

Diagnostics

DataTrak can diagnose several problems with the

pump. When the monitor detects a problem, the LED

(CD, See F

IG

. 31) will flash and a diagnostic code will

appear on the display. See Table 1.

To acknowledge the diagnosis and return to the normal

operating screen, press once to wake up the dis-

play, and once more to clear the diagnostic code screen

Operation

3A2012J 37

Table 1: Diagnostic Codes

Symbol Code Code Name Diagnosis Cause

Runaway

(DataTrak only)

Pump running faster than set

runaway limit.

•

Increased air pressure.

•

Increased fluid output.

•

Exhausted fluid supply.

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

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

E-3 Low Battery Battery voltage too low to stop

runaway.

Low battery. Replace battery;

see page 38.

E-4 Service

Component 1

(units with

runaway

protection only)

Problem with stopping runaway.

•

Damaged solenoid.

•

Damaged valve carriage.

•

Runaway (RT, F

IG

. 31) pro-

tection may be enabled with

pump that is not equipped

with a runaway solenoid

valve. Enter setup screen

and disable runaway protec-

tion.

E-4 Disconnected

Solenoid

(units with

runaway

protection only)

Solenoid is disconnected.

•

Solenoid unplugged.

•

Damaged solenoid wires.

Solenoid is not engaging piston

cup.

•

Bracket and solenoid not

tight against air valve hous-

ing.

E-5 Service

Component 2

Problem with sensing valve

movement.

•

Sensors unplugged.

•

Sensors mounted incor-

rectly.

•

Damaged sensors.

•

Damaged valve carriage.

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

see page 38.

•

Faulty solenoid or solenoid

wiring.

•

Extreme temperatures

(above 140°F [60°C]).

•

Runaway (RT, F

IG

. 31) pro-

tection may be enabled with

pump that is not equipped

with a runaway solenoid

valve. Enter setup screen

and disable runaway protec-

tion.

Operation

38 3A2012J

Replace DataTrak Battery or Fuse

Replace Battery

1. Unscrew cable from the back of the reed switch

assembly. See F

IG

. 33.

2. Remove the cable from the two cable clips.

3. Remove DataTrak module from bracket. Take mod-

ule and attached cable to a non-hazardous location.

4. Remove two screws on back of module to access

battery.

5. Disconnect the used battery and replace with an

approved battery. See F

IG

. 34.

Replace Fuse

1. Remove the screw, metal strap, and plastic holder.

2. Pull the fuse away from the board.

3. Replace with a new fuse.

The battery and fuse must be replaced in a

non-hazardous location.

Use only the following approved replacement batter-

ies. 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.

F

IG

. 33. Disconnect DataTrak

ti11992a

F

IG

. 34. DataTrak Battery and Fuse Location

ti11994a

Battery

Fuse

Solenoid Cable

Connection

Sensor Cable

Connection

Maintenance

3A2012J 39

Maintenance

Components

See component manuals listed on page 3 for mainte-

nance schedules and procedures for each component.

Task Schedule

Inspect pump wetcup

and fill with TSL and

remove any particles or

residue

Daily

Remove resin pump

outlet filter and flush

debris

Daily

Inspect hoses for wear

or damage and replace

immediately if found

Weekly

Remove catalyst

reservoir filter and

clean with solvent

As needed

Replace catalyst

reservoir filter

As needed

Flush system As needed

Troubleshooting

40 3A2012J

Troubleshooting

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.

Resin Pump

See Resin Pumplines on page 61 for parts identification.

Follow Pressure Relief Procedure and Shutdown

on page 24 before checking or servicing the equip-

ment.

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.

Worn weep seals. Replace weep cartridge.

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

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

Scratched piston rod. Replace piston rod.

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

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

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

Loose bearing. Tighten bearing.

Pressure being relieved through relief

valve or check valve at a low pressure.

Relief valve or check valve has a weak

spring.

Replace relief valve or check valve.

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

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

Worn or damaged snap-on seal retainer Remove and replace

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)

See DataTrak Operation-Runaway Monitor,

page 35.

Stall on bottom of

stroke.

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

Runaway, page 35, to reset the runaway solenoid.

Troubleshooting

3A2012J 41

* 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.

Output low on both

strokes.

Air line restricted or air supply inadequate. Valves

closed or clogged.

Clear air line; increase air supply. Check that

valves are open.

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

Air motor icing. See air motor manual for instructions.

Exhausted fluid supply. Refill and prime pump.

Worn piston packings. Replace.

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

Pump output low on

only one stroke.

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

Worn piston packings. Replace.

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

Pump operates errati-

cally.

Exhausted fluid supply. Refill and reprime pump.

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

Worn piston packing. Replace.

Suction tube too restrictive, causing pump to cavi-

tate

Use larger diameter tube

Erratic accelerated

speed.

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

High viscosity fluid. Reduce viscosity; increase fluid temperature,

reduce flow rate by using smaller tip.

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

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

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

Filler material clumping causing extra friction on

rods and seals.

Flush pump and replace packings.

Cycles or fails to hold

pressure at stall.

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

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

PTFE tape on connections.

Poor finish or irregular

spray pattern.

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

mendations.

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

ommendations.

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

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

Remove inlet ball, flush dried material, re-install

inlet ball.

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

increase hose diameter (especially cold or viscous

material.

Problem Cause Solution

Repair

42 3A2012J

Repair

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 com-

patible with your system.

Disconnect the Displacement

Pump

See manual 3A2313 for displacement pump service and

parts information.

1. Flush the pump, see page 30.

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

3. Relieve the pressure, see page 24.

4. Disconnect the air supply and fluid hoses.

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).

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 possi-

ble.

9. Protect hands with a

rag then unscrew the

displacement pump by

hand and place on

work bench.

10. See displacement pump manual 3A2313 for pump

service procedures and parts information.

• To reduce the risk of fire and explosion, repair pro-

cedures 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 con-

tain catalyst or resin.

Threads are very sharp. Use a rag to protect hands

when hand turning or carrying the pump.

ti12815a

ti12812a ti12813a

A

C

B

ti12816a

Repair

3A2012J 43

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 dis-

placement 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 dis-

placement rod.

Hand tighten the

coupling nut (A).

7. Screw the displacement pump into the adapter

plate (D) until the cylinder top is flush with the top of

the adapter plate.

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

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

place.

10. Hold the flats of the motor rod with a wrench. Use

another wrench to tighten the coupling nut (A).

Torque to 75-80 ft-lb (102-108 N•m).

11. Reconnect air supply to motor.

F

IG

. 35. Align cylinder and adapter plate.

ti12817a

B

A

ti12814a

Cylinder, not

be flush with

plate.

wet cup, should

D

Repair

44 3A2012J

Disconnect the Air Motor

See manual 3A2315 for air motor service and parts

information. See F

IG

. 36 on page 45.

1. Relieve the pressure, see page 24.

2. Disconnect main air supply line from the inlet on the

air control panel (AE).

3. Disconnect grounding wire.

4. Disconnect items from the air motor:

a. Note location of all air hoses connected to air

motor then disconnect the hoses from the air

motor.

b. Remove top pin (AA) connecting upper catalyst

pump arm to air motor, then remove bolts (AB)

connecting lower catalyst pump arm to air motor

then remove catalyst pump and control arms

assembly (AC).

c. Remove two bolts (AD) securing air control

panel to air motor then remove air control

panel (AE).

5. Hold the flats of the air motor piston rod with a

wrench. Use another wrench to loosen the coupling

nut (A). Lower the coupling nut (A) enough to

remove the coupling collars (B), then remove the

coupling nut (A).

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

7. Use a 13 mm socket to loosen the top two

screws (AG) that secure air motor to mounting

bracket (AH).

8. Lift up on the air motor to remove it. The tie

rods (AJ) will remain attached to the air motor.

9. Use a socket on the flats of the tie rods (AJ) to

remove them from the bottom of the air motor.

10. See air motor manual 3A2315 for repair procedures

and parts information.

Reconnect the Air Motor

See F

IG

. 36 on page 45.

1. Screw the tie rods (AJ) into the bottom of the air

motor. With a wrench on the flats of the tie rods,

torque to 50-55 ft-lb (68-75 N•m).

2. Align the tie rods (AF) with the holes in the pump

adapter. Carefully lower the air motor into place.

3. Attach the tie rod nuts (AF) to tie rods then torque to

50-60 ft-lb (68-81 N•m).

4. Install and tighten the screws (AG) that secure air

motor to mounting bracket (AH).

5. Install coupler spring guard and TSL reservoir.

6. With coupling

collars (B) in

place, hand

tighten the cou-

pling nut, then

torque to

75-80 ft-lb

(102-108 N•m).

7. Connect the air

and fluid hoses.

8. Attached grounding wire to true earth ground.

ti12812a ti12813a

A

C

B

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

ti12817a

B

A

Repair

3A2012J 45

F

IG

. 36

AA

AB

AC

AE

AD

AF

AJ

AG

AH

AK

ti18456c

Repair

46 3A2012J

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

IG

. 36 on

page 45:

a. Note location of all air hoses connected to air

motor then disconnect the hoses from the air

motor.

b. Remove top pin (AA) connecting upper catalyst

pump arm to air motor, then remove bolts (AB)

connecting lower catalyst pump arm to air motor

then remove catalyst pump and control arms

assembly (AC).

c. Remove two bolts (AD) securing air control

panel to air motor then remove air control

panel (AE).

5. Disconnect the air and fluid hoses.

6. Disconnect the ground wire.

7. Use a socket to loosen the two screws (AG) con-

necting the air motor to the mounting bracket (AH).

8. Use a socket to remove the two screws (AK) secur-

ing 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.

Repair

3A2012J 47

Repair Catalyst Pump

See F

IG

. 37 on page 49 for reference numbers.

Remove Catalyst Pump from System

1. Flush the pump, see page 30.

2. Relieve the pressure, see page 24.

3. Close catalyst supply ball valve and disconnect fluid

lines.

4. Remove top pivot knob securing catalyst pump to

upper control arm.

5. Remove bolt securing catalyst pump to lower con-

trol arm then remove catalyst pump.

Disassemble Catalyst Pump

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

pump rod (910).

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

housing (901).

8. Holding the slave pump housing (901) stationary

with one hand, use a crescent wrench on the flats of

the slave pump cylinder (918) to loosen then

remove the cylinder and foot valve (922) assembly.

9. Place the slave pump housing (901) in a vise. Use

the flats provided by the quick-release pin (908)

hole.

10. Use a crescent wrench on the flats of the

cartridge (902) to loosen then remove the cartridge

and piston rod (910) assembly.

Repair Throat and Piston Seals

11. Use a wrench on the flats of the piston rod (910) to

hold it stationary while using a second wrench on

the flats of the transfer housing (914) to loosen then

remove the housing and cap (917) assembly.

12. Install bullet tool 16D007 on the piston rod (910)

then pull the rod (910) out of the cartridge (902).

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

seal (902f).

14. Use crescent wrench to loosen then remove the

bearing (902b) and felt wiper (902d) assembly.

15. Remove seal (902f) from inside of cartridge (902a).

16. Remove o-ring (902g).

17. Install new seal (902f) into bottom of the

cartridge (902a) with the u-cup opening facing into

the pump.

18. Install seal (902f) with onto weep seal installation

tool 16N967 with u-cup opening facing into the

pump then use tool to install seal into inside of

cartridge (902a).

19. Install felt wiper (902d) and bearing (902b) into

cartridge (902a). Tighten to 20-60 in-lb

(2.3-6.8 N•m).

20. Install o-ring (902g).

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

22. Lubricate the piston rod.

23. With bullet tool 16D007 installed on the piston rod,

install cartridge assembly (902) onto the rod.

24. Remove the bullet tool.

25. Use one wrench on the transfer housing (914) and

another on the transfer housing cap (917) to break

them loose from each other then remove the cap

from the housing.

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

housing.

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

from transfer housing.

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

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

NOTICE

Bullet tool 16D007 must be used or damage to the

seals will result when removing or installing items

onto the rod.

Repair

48 3A2012J

30. Hold spring (911) upright, place valve (912) on top

of spring, slide transfer housing (914) upside down

over the spring then flip upright.

31. Install transfer housing (914) onto piston rod (910).

Use flats on rod and transfer housing to torque

transfer housing against the piston rod to 30-50 in-lb

(3.4-5.6 N•m).

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

housing (914).

33. Install u-cup (915) onto transfer housing with u-cup

opening facing up towards the rod.

34. Install guide (916) onto transfer housing.

35. Install transfer housing cap (917) onto transfer

housing. Use flats to torque to 30-50 in-lb

(3.4-5.6 N•m).

Repair Foot Valve

36. Use wrench to loosen lock nut (921) then remove

cylinder (918) from foot valve (922).

37. Remove ball (925) from foot valve.

38. Remove backup o-ring (920) and o-ring (919) from

both ends of the cylinder (918).

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

to aid ball seat removal.

40. Place new ball seat onto seat installation tool

16N996 with lip opening facing in towards tool.

41. Place tool into foot valve then tap with a hammer

until ball seat is properly seated then remove tool.

42. Install new backup o-ring (920) and o-ring (919)

onto both ends of the cylinder (918). Make sure to

install the o-rings in the correct position, with the

backup o-rings towards the center of the cylinder.

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

o-rings (919).

44. Install ball into foot valve.

45. Thread cross-cut end of cylinder into foot valve by

hand until it bottoms out but do not tighten the jam

nut.

Assemble Catalyst Pump

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

housing (914).

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

48. Apply thread sealant to the threads of the

cartridge (902a).

49. With the slave pump housing (901) in a vise, care-

fully 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).

Repair

3A2012J 49

F

IG

. 37: Catalyst Pump Details

911

912

913

914

915

916

917

918

920

919

925

923

921

940

945

924

922

903

903a

903b

903c

932 947

901

902

910

926

928

929 927

935

946

909

907

909

908

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.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

511 5

12

12

2

1 4

1

1

6

1

6

6

8

7

5

11

1

910

6

8

11

51

3

3

919

920

924

11

8

902d

902b

902a

902f

902f

902g

902e

14

13

ti19060a

932

947

939

938

939 947 937

946

934

1

1

1

1

1

1

External Mix Only

Internal Mix shown

ti21344a1

1

930

1

System Parts

50 3A2012J

System Parts

Systems

107

106

121

114,115,116

108

110

105

111

102

104

108

113

103

109

122

113

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).

1

4

5

7

8

5

1

8

8

7

4

4

104

ti19056b

152

System Parts

3A2012J 51

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.

◆Item not shown.

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

Ref. Part Description

16R001

16R002

16R003

16R004

16R005

16R006

16R009

16R012

16R015

16R018

16R021

16R024

16R027

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 114109 FITTING, 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 124071 PLUG, 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

152 24M692SPACER, ball joint 1111111111111

System Parts

52 3A2012J

◆Item not shown.

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

Ref. Part Description

16R030

16R033

16R036

16R039

16R044

16R047

16R050

16R053

16R056

16R059

16R062

16R065

16R068

16R071

16R074

16R079

16R082

16R085

16R088

16R091

16R094

16R097

102 16N918 WALL OR POLE MOUNT KIT

(No Cart)

1111 1111

--- 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

1/4mnpt

22222222222

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

System Parts

3A2012J 53

◆Item not shown.

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

Ref. Part Description

16R100

16R103

16R106

16R109

16R114

16R117

16R120

16R123

16R126

16R129

16R132

16R135

16R138

16R141

16R144

16R149

16R152

16R155

16R158

16R161

16R164

16R167

102 16N918 WALL OR POLE MOUNT KIT

(No Cart)

1111 1111

--- 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

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 111111111111111

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

System Parts

54 3A2012J

◆Item not shown.

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

Ref. Part Description

16R170

16R173

16R176

16R179

16R184

16R187

16R190

16R193

16R196

16R199

16R202

16R205

16R208

16R211

16R214

102 16N918 WALL OR POLE MOUNT KIT

(No Cart)

1111 1111

--- CART, for use with boom 1111

--- CART 111

103 W13DFC PUMP, FRP, 13:1

W17CFS PUMP, FRP, 17:1 111111111111111

104 111799 SCREW, cap, hex head 666666666666666

105 16P125 HARNESS, slave linkage 111111111111111

106 119999 BOLT, shoulder 111111111111111

107 24M092 PIN, quick release, 1.5 x 0.25 111111111111111

108 16N741 PUMP, slave, external mix 1111

16N740 PUMP, slave, internal mix 11111111111

109 120476 BOLT, shoulder, 5/16 111111111111111

110 111040 NUT, lock, insert, nylock, 5/16 111111111111111

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

16M565 LABEL, ratio, 17:1, FRP 111111111111111

112◆16N761 BOOM KIT 1111

113 16U750 PANEL, air control 111111111111111

114 113093 FITTING, connector, 1/4 nptf 111111111111111

115 114109 FITTING, elbow, male, swivel

121141 FITTING, elbow, swivel, 3/8t

1/4mnpt

22222222222

16D939 FITTING, nipple, reducing 1111

116 114109 FITTING, elbow, male, swivel 1111

121141 FITTING, elbow, male, swivel

118 --- TUBING, nylon, round 33333333333

119◆238909 WIRE, grounding 111111111111111

121 --- TUBE, nylon, round 333333333333333

122 124071 PLUG, fitting, push-to-connect 111111111111111

123◆16M588 HOSE, bundle, 25 ft external gel 1

16M587 HOSE, bundle, 25 ft internal gel 11

16M586 HOSE, bundle, 25 ft chop

16M591 HOSE, bundle, 35 ft external gel 1

16M590 HOSE, bundle, 35 ft internal gel 111

16M589 HOSE, bundle, 35 ft chop

16M585 HOSE, bundle, 50 ft external gel 1

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 11 111 111

125◆16M736 SUPPLY HOSE, 55 gallon 111111111111111

126◆16M810 KIT, FRP 111111111111111

151◆ ▲16D136 LABEL, warnings 111111111111111

152 24M692 SPACER, ball joint 111111111111111

System Parts

3A2012J 55

Carts

◆Included in Catalyst Outlet Kit 16N854.

201

202

204

203

205

Apply sealant to threads.

1

1

210

211

207

209

2081

Ref Part Description

Quantity

Cart, for

use with

boom

Cart, not

for use

with boom

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

System Parts

56 3A2012J

System Parts

3A2012J 57

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.

◆Included in pipe clamp kit 16P291.

302

301

303

304

305,306,307,308

309,310,311

ti18528c

312

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

System Parts

58 3A2012J

Boom, 16N761

◆Not shown.

--- Not for sale.

Item shown for reference only.

2 in. ID schedule 40 pipe not included.

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

1

2

ti19076a

401

401

413

407

411

410

408

412

412

409

414 406 405

404

403

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

System Parts

3A2012J 59

Air Panel

512

525

533

501

517

506

505

503

514

509

522

515

541

510

Plug supplied with regulator (504).

Apply sealant to all non-swiveling pipe threads.

1

2

504

522

511

502

539

522

531

519

529

1

ti19058b

510

537 542

540

527

520

509

504

521

538

541

509

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

2

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

1/8fnpt

3

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

npt(m) x 5/32 OD tube

1

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)

2

517 16U556 LABEL, air control panel, FRP 1

519 124071 PLUG, fitting, push-to-connect 1

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

polyurethane

0.18

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 96/0005-

2/99

WASHER, lock, ext, #10, ms 2

538 16U452 FITTING, elbow, 1/4npt(m) x

1/2 tube

1

539 16U479 FITTING, cross, 1/2 tube,

plastic

1

540 16U480 FITTING, 1/2 stem x 1/2npt(m),

plastic

1

541 16U481 FITTING, tee, 1/4 npt(m), 3/8 t,

1/4 npt(f)

2

542 105332 NUT, lock 2

Ref Part Description Qty

System Parts

60 3A2012J

Slave Pump Linkage, 16P125

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

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

rately.

ti19057a

2001a 2001c

2006

2002

2007

2001b

2001e

2001d

2001f

2003 2004

2005

2008

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

System Parts

3A2012J 61

Resin Pumplines

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

correct kit for your pump.

†See Resin Pumpline Kits on page 62.

612

604

605

603

608

607

602

606

616 611

610

601

613

615

614

617

609

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.

1

2

3

4

5

6

7

3

5

7

4

6

1

2

3

618

Ref Part Description

Quantity

W13DFC,

13:1

W17CFS,

17:1

601 M07LNL MOTOR, double

ended, 4.5 in.

1 1

602* 15M662 ROD, tie 3 3

603* 16U435 ADAPTER, dis-

placement pump

1

16U426 ADAPTER, dis-

placement pump

1

604 LW100C PUMP, 100 cc 1

LW075S PUMP, 75 cc 1

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

606*† 24A619 COLLAR, coupling

(10 pack)

2 2

607* 15T311 NUT, coupler 1 1

608* 24A625 RESERVOIR, TSL,

75cc lower

(includes 618)

1

24A626 RESERVOIR, TSL,

100cc lower

(includes 618)

1

609 16N774 LINK, yoke, upper 1 1

610 16M362 LINK, fixed, pivot 1 1

611 116596 SCREW, cap, hex

head

2 2

612 24F620 FILTER, fluid,

5000 psi

1 1

613 24D642 MUFFLER 1 1

614 100361 PLUG, pipe 1 1

615 16M355 FITTING, adapter,

muffler, 1/2 npt x

1in. - 14

1 1

616* 16M477 SPRING, guard 1 1

617 15V204 FITTING, elbow,

1/2 npt x 1/2 tube

1 1

618*† --- O-RING, wetcup 1 1

System Parts

62 3A2012J

Resin Pumpline Kits

NOTE: For displacement pump repair kits, see man-

ual 3A2313. For air motor repair kits, see manual

3A2315.

Air Motor and Pump for

Resin Pumpline

See air motor manual 3A2313 and pump manual

3A2315 for parts identification.

Gun

See RS gun manual 3A0232 for parts identification.

Kit Description LW075S LW100C

Wet-Cup O-Ring (618)

Package of 10 24A631 24A632

Coupling Collars (606)

Package of 10 24A619 24A619

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).

16N242 16N243

System Parts

3A2012J 63

Resin Filter

24F620

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

* Strainer Options:

Press fit spring (710) to bottom of filter

bowl (701).

Apply thread lubricant.

Apply grease.

Apply thread sealant to all

non-swiveling pipe threads.

3

4

5

6

706

702

708

719

710

707

701

711

703

720

704

705

3

5

4

ti19059a

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

1

719 * STRAINER, 100 mesh screen 1

720 155541 FITTING, swivel, elbow 1

Mesh 2-pack 25-pack

30 224458 238436

60 224459 238438

100 224468 238440

200 224469 238442

System Parts

64 3A2012J

Resin Supply Hose

16M736

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

100 mesh (20397-02).

805

804

803

802

801

807

Apply pipe sealant to all

non-swiveling pipe threads.

1

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

1

System Parts

3A2012J 65

System Parts

66 3A2012J

Catalyst Slave Pumps

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).

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

902d

902b

902a

902f

902f

902g

902e

14

13

ti19060a

932

947

939

938

939 947 937

946

934

11

1

1

1

1

External Mix Only

WLE

911

912

913

914

915

916

917

918

920

919

925

923

921

940

945

924

922

903

903a

903b

903c

932 947

901

902

910

926

935

946

909

907

909

908

12

12

2

1 4

1

1

6

1

6

6

8

7

5

11

1

910

6

8

11

51

3

3

919

920

924

11

8

Internal Mix shown

1

930

1

936

115

940

1

Series D only

Series D

only

System Parts

3A2012J 67

Catalyst Pumps

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

Ref. Part Description

Qty.

16N740, for Internal Mix

16N741, for External Mix

901 --- HOUSING, slave pump 1 1

902 24C479 KIT, cartridge, FRP 1 1

902a --- CARTRIDGE, slave pump 1 1

902b

†

--- BEARING, cartridge 1 1

902d

†

--- WIPER, felt, piston rod 1 1

902e

✿

16P186 SEAL, snap on, cartridge 1 1

902f

✿

16A981 SEAL, slave pump weep 2 2

902g

✿

123556 O-RING, silicone #016 1 1

903 16N975 VALVE, 3000 psi blow off (also

includes 903a, 903b, and 903c)

1 1

903a 224807 BASE, valve 1 1

903b 15C780 HANDLE 1 1

903c 15C972 PIN, spring 1 1

907 113641 GAUGE, pressure, fluid 1

124432 GAUGE, 160 psi 1

908 123595 PIN, quick release 1 1

909 124193 CABLE, lanyard, 5 inch 1 1

910 16N964 ROD, piston, slave pump (also

includes 919, 920, and tool

16D007)

1 1

911

★

123636 SPRING, transfer housing 1 1

912

★

16K928 VALVE, poppet 1 1

913

★

123934 O-RING, 003, FKM 1 1

914 16K960 HOUSING, transfer, etched 1 1

915

★

LPA-126 SEAL, radial 1 1

916

★

LPA-127 GUIDE, piston 1 1

917 16A666 CAP, transfer housing 1 1

918 16N965 CYLINDER, slave pump (also

includes 919 [Qty 2] and 920

[Qty 2])

1 1

919

✿‡

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

920

✿‡

124061 RING, backup, 0.518 ID,

0.053 wide

2 2

921 LPA-144 NUT, lock 1 1

922 16N976 HOUSING, inlet, slave 1 1

923

‡

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

924 --- BEARING, flanged, 0.375 ID 2 2

925 LPA-134-02 BALL, spherical 1 1

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

jic

1 1

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

935 110208 PLUG, pipe, headless 1

936 94/0320-1/98 FITTING, nipple, 1/4; series D

only

1 1

937 124379 VALVE, check, npte x npti, 100

psi

1

938 16V706 FITTING, tee, compression, 1/4 1

939 --- TUBE, polyethylene 0.5

940 24U857 VALVE, ball, mini; no tused on

series D

1 1

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

series D only

1 1

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

946 16V704 FITTING, 1/8 npt x 1/4 tube, 90,

sst

1 1

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

Ref. Part Description

Qty.

16N740, for Internal Mix

16N741, for External Mix

System Parts

68 3A2012J

Catalyst Reservoir

16P425

1001

1002

1010

1001

1011

Apply pipe sealant to threads.

Apply sticker so that the level

line is even with the 2.5 gallon

mark on tank (1001).

1

2

1

2

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

1012

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

2

1012 16M738 LABEL, hazardous material

diamond

1

System Parts

3A2012J 69

Cart not included in kit, shown for reference only

System Parts

70 3A2012J

Hose Bundles

1114

1102

1104

1109

1101

1111

1107

1103

1113

1108

1102 (Catalyst)

1105 (External Atomizing Air/

Internal Chop AAC Air)

1101 (Chopper

Air/Internal Gel AAC)

1103 (Resin)

1104 (Internal Solvent/

External AAC)

1115

1106

ti21345a1

1105

System Parts

3A2012J 71

Hose Bundles

▲Replacement Danger and Warning labels, tags and cards

are available at no cost.

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

hose. The extra resin hose is coiled at the factory and is

part of the pressure surge suppression system.

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

later chop hoses are shown in the table.

◆Not shown.

Ref Part Description

Quantity

16M583,

50 ft,

chop

16M584,

50 ft

internal

gel

16M585,

50 ft

external

gel

16M586,

25 ft,

chop

16M587,

25 ft,

internal

gel

16M588,

25 ft,

external

gel

16M589,

35 ft,

chop

16M590,

35 ft,

internal

gel

16M591,

35 ft,

external

gel

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

ene, 28 ft

1

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

ene, 38 ft

1

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

ene, 53 ft

1

590570 TUBE, 1/2 IN., polyethyl-

ene

53 ft 28 ft 35 ft

1102 24C540 HOSE, coupled, 1/8 in.,

3000 psi, 28 ft

111

24C541 HOSE, coupled, 1/8 in.,

3000 psi, 53 ft

1 1 1

24G429 HOSE, coupled, 1/8 in.,

3000 psi, 35 ft

1 1 1

1103

†

240797 HOSE, coupled, 3/8 x

50 ft

1 1 1 1 1 1

277253 HOSE, coupled, 1/2 in. x

50 ft

1 1 1

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

nylon, 28 ft

111

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

nylon, 53 ft

1 1 1

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

nylon, 40 ft

1 1 1

1105 --- TUBE, polyethylene,

0.250 outer diameter

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

1106 124427 JACKET, blue scuff 22ft 222

124428 JACKET, blue scuff 47ft 1 1 1

16M599 JACKET, blue scuff 29ft 1 1 1

1107 16M606 JACKET, blue scuff 15ft 1 1 1

1108 158256 UNION, swivel 1 1 1

1109 277249 HOSE, coupled, 1/4 in. x

3 ft, 4000 psi

111111111

1110◆744 GUIDE, roving, hose 1 1 1

1111

▲

16D659 LABEL, warning, hose

bundle

111111111

1112 114271 STRAP, retaining 1 1 1 1 1 1

1113 123379 FITTING, reducer,

3/8 nptx1/4 npt

1 1 1 1 1 1

162449 FITTING, nipple, reducing 1 1 1

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

ene

2.5 ft 2.5 ft 2.5 ft

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

OD tubing

1 1 1

System Parts

72 3A2012J

Accessory Parts

Heater Kits

1201

1202c

1202f

1202b

1210

1202a

1204

1206

ti21347a

1215 1213

1211

1203

1202e

1202d

1205 1204

1202d

1214

1210

1204

1203

1202d

1202a

1202b

1202f 1202e

1202d

1202a

1202c

1215

1214

1210

1213

1211

1208

ti21346a

1213

1210

1

Use 1/2-14 npt x 3/8-18 npt fitting for gel systems.

Use 1/2-14 npt x 1/2-14 npt fitting for chop systems.

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

fitting (1214).

1

2

2

1213

1

1

1

16N014 and 16N015 Kits

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

System Parts

3A2012J 73

Heater Kits

* Items are available in heater hardware kit 16N119.

† Parts available in pipe clamp kit 16P291.

★Heaters can be disassembled to remove cured material.

Ref Part Description

Quantity

16N014,

120v, FM

★

16N015,

240v, FM

★

16N016,

120v,

hazardous

16N017,

240v,

hazardous

16N018,

120v, non-

hazardous

16N019,

240v, non-

hazardous

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

111111

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

1213* 155470 SWIVEL, union, 90°; 1/2

x 1/2 npt

222222

1214* 217430 SWIVEL, union, 90°; 1/2

x 3/8 npt

111111

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

1

226816 HEATER, viscon, 120

volt

1

System Parts

74 3A2012J

Solvent Pressure Pot Kits

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

1304

1305

1302

1301

1303

1309

1310

1306

1307 1311

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.

1

2

3

2

2

2

2

1

2

2

2

3

Ref Part Description Qty

1301 20324-00 TANK, solvent, 2 gallon

(assembly 16M893 only)

1

20324-01 TANK, solvent, 5 gallon

(assembly 16M894 only)

1

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

1

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

3/8 tube

1

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

1

1310 3165 VALVE, ball, 2-way,

3/8 female, 3/8 male

1

1311 17440-00 CLAMP, grounding 1

System Parts

3A2012J 75

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

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

1408

1411

1406

1410

1408

1412

1401

1404

1401

1403

1402

1409

1406

1401 1405

1414

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.

1

2

3

1

1

1

1

1

1

1

1

3

Ref Part Description Qty

1401 236086 TANK, pressure assy, 2 gal.

(assembly 16M874 only)

1

236087 TANK, pressure assy, 5 gal.

(assembly 16M875 only)

1

1402 165053 PACKING, o-ring 1

1403 188880 PLUG, lid 1

1404 188784 NUT, jam, hex 1

1405 171976 TUBE

(assembly 16M875 only)

1

185531 TUBE, siphon (assembly

16M874 only)

1

1406 --- BUSHING, hex, 3/8npt x 1/4npt,

male/female

2

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

1

1413 210575 CAP, filler (assembly 16M875

only, not shown)

1

1414 176347 LABEL, identification 1

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)

1

Ref Part Description Qty

System Parts

76 3A2012J

Solvent Diaphragm Pumps

2-gallon 16M560 and 5-gallon 16M561

Base System shown for reference only

1501,1503

1502,1503

1504

1505

Ref Part Description Qty

1501 16M559 PUMP, solvent, FRP, flush 1

1502 16M652 TANK, solvent, 2.5 gal assembly

(assembly 16M560 only)

1

16M651 TANK, solvent, 5 gal assembly

(assembly 16M561 only)

1

1503 16M769 KIT, pump fasteners 1

1504 --- TUBING, nylon, round 3

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

(16M560 only)

1

16N892 KIT, pick-up tube, 5 gallon

(16M561 only)

1

System Parts

3A2012J 77

DataTrak Upgrade Kit

16M881

* See FRP air motor manual.

1602

1602

Ref Part Description Qty

1601 * 24A354 SMART AIR VALVE (not shown) 1

1602 24A576 DATATRAK CONVERSION KIT 1

System Parts

78 3A2012J

Carts for 55 Gallon Barrel,

16M896

--- Not for sale.

WLE

1701

1717

1703

1702

1716

1711

1714

1715

1713

1706 1712

1710

1709

1708

1708

1707

1705

1718

1704

1704, 1705, 1718

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

System Parts

3A2012J 79

Roving Box Bracket

16M961

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

side by side.

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

1802

1801

1803

1806

1804,1805

1807†

NOTE: Second roving box shown for reference only to illus-

trate installation.

ti18525b

System Parts

80 3A2012J

Extension Hoses

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

*

Series C and prior chop hoses use 123554. Series D or

later chop hoses are shown in the table.

1904

1901

1907 1903

1906

1913 1902

1903, 1907 (Resin) 1904, 1912 (Internal Solvent/

External AAC Air)

1902, 1909 (Catalyst)

1905, 1911 (External Atomizing Air/

Internal Chop AAC Air)

1901, 1910 (Chopper Air/

Internal Gel AAC)

Chop Hose

Gel Hose

1905

1907 1903 1913

1906

1902

1904

1905

ti21348a

Ref Part Description

Quantity

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,

25 ft

1 1 1

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

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

4000 psi

1

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

25 ft

1 1 1

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

Dimensions

3A2012J 81

Dimensions

Cart and Boom

¡

¡

C

A

B

ti18526b

Ref.

A

(Max Width)

B

(Max Height)

C

(Max Depth)

E

(Radius)

F

(Radius)

Description

144 in.

(3658 mm)

100 in.

(2540 mm)

192 in.

(4877 mm)

144 in.

(3658 mm)

72 in.

(1828 mm)

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

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

Top View

E

F

Dimensions

82 3A2012J

Cart Only

Wall/Pole Mount

Ref. Cart Only

A

(Max Width)

29.5 in.

(749 mm)

B

(Max Height)

47.75 in.

(1213 mm)

C

(Max Depth)

32.5 in.

(826 mm)

ti18496b

B

A

C

Ref. Wall/Pole Mount

A

(Max Width)

39.0 in.

(991 mm)

B

(Max Height)

46.6 in.

(1183 mm)

C

(Max Depth)

32 in.

(813 mm)

ti18524d

A

B

C

Technical Data

3A2012J 83

Pumpline Wall Mounting Bracket Dimensions

The pumpline bolts directly to this mounting plate.

Technical Data

System Technical Data

* Maximum fluid temperature rating determined by

lowest rated component in system.

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

WLD

10.1 in.

(257 mm)

3.52 in.

(89.4 mm)

Four 0.60 in. (15 mm)

mounting holes

Technical Data

84 3A2012J

Pumpline Technical Data

Catalyst Pump Technical Data

** 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

Resin Pump, Catalyst Pump, Solvent Pump, and Heater Technical Data

See component manuals listed on page 3 for 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

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

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

Technical Data

3A2012J 85

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

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

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

This manual contains English. MM 3A2012

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

Copyright 2012, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revised June 2014

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in

material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty

published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by

Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written

recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty

installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of

non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with

structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or

maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of

the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned

to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs

will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT

LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or

consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

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

warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or

the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the

negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,

given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la

rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite

de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

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

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

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505