GlasCraft Chop System External...Warnings 4 3A1195D Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point

Instructions - Parts

GlasCraft Chop System External

Low emission external-mix gel coat chop system. For use with polyester resin and gel coat. For professional use only.

See page 3 for model information and approvals.See page 30 for maximum working pressure.

Important Safety InstructionsRead all warnings and instructions in this manual. Save these instructions.

3A1195DENG

Related Manuals

2 3A1195D

ContentsRelated Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Important Methyl Ethyl Ketone Peroxide (MEKP)

Safety Information . . . . . . . . . . . . . . . . . . . . . . . 6Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 13Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Flush Before Using Equipment . . . . . . . . . . . . . 16Pressure Relief Procedure . . . . . . . . . . . . . . . . 16Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chop System External Parts . . . . . . . . . . . . . . . 22SSP-175 Safety Guard Kit . . . . . . . . . . . . . . . . 23LPA-165 Catalyst Bottle . . . . . . . . . . . . . . . . . . 24LPA-170 Catalyst Bottle Bracket . . . . . . . . . . . . 24GAM-268-01 Material Pick-up Kit . . . . . . . . . . . 2524G534 Air Manifold . . . . . . . . . . . . . . . . . . . . . 2624G535 Air Manifold . . . . . . . . . . . . . . . . . . . . . 2721460-00 Heater Conversion Kit . . . . . . . . . . . . 28

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 32

Related ManualsComponent Manuals in U.S. English:

Manual Description

3A1218 GlasCraft Catalyst Pump Repair-Parts

3A0232 RS Gun, Cutter Operation-Repair

GC-1303 20864- Series Operation

GC-1360 FRP 22026-01 Parts List

Models

3A1195D 3

Models

❖

Ta = -20°C to +38°C.

❄

Ta = -20°C to +38°C.

NOTE: Ex certification applies only to systems that do not include heaters. If a heater is added to an Ex certified system, the system no longer complies with the Ex directive.

Model MountingPump Ratio Heater

Hose Bundle

24G253 Cart 11:1 120 Vac 25 ft.

24G254 Cart 11:1 120 Vac 35 ft.

24G255 Cart 11:1 120 Vac 50 ft.

24G256 Cart 11:1 120 Vac none

24G257 Cart 11:1 240 Vac 25 ft.

24G258 Cart 11:1 240 Vac 35 ft.

24G259 Cart 11:1 240 Vac 50 ft.


❖24G261 Cart 11:1 none 25 ft.

❖24G262 Cart 11:1 none 35 ft.

❖24G263 Cart 11:1 none 50 ft.

❖24G264 Cart 11:1 none none

24G265 Cart 17:1 120 Vac 25 ft.

24G266 Cart 17:1 120 Vac 35 ft.

24G267 Cart 17:1 120 Vac 50 ft.


24G269 Cart 17:1 240 Vac 25 ft.

24G270 Cart 17:1 240 Vac 35 ft.

24G271 Cart 17:1 240 Vac 50 ft.


❄24G273 Cart 17:1 none 25 ft.

❄24G274 Cart 17:1 none 35 ft.

❄24G275 Cart 17:1 none 50 ft.

❄24G276 Cart 17:1 none none

24G277 Cart 20:1 120 Vac 25 ft.

24G278 Cart 20:1 120 Vac 35 ft.

24G279 Cart 20:1 120 Vac 50 ft.


24G281 Cart 20:1 240 Vac 25 ft.

24G282 Cart 20:1 240 Vac 35 ft.

24G283 Cart 20:1 240 Vac 50 ft.


❖24G285 Cart 20:1 none 25 ft.

❖24G286 Cart 20:1 none 35 ft.

❖24G287 Cart 20:1 none 50 ft.

❖24G288 Cart 20:1 none none

24G289 none 11:1 120 Vac 25 ft.

24G290 none 11:1 120 Vac 35 ft.

24G291 none 11:1 120 Vac 50 ft.

24G292 none 11:1 120 Vac none

24G293 none 11:1 240 Vac 25 ft.

24G294 none 11:1 240 Vac 35 ft.

24G295 none 11:1 240 Vac 50 ft.


❖24G297 none 11:1 none 25 ft.

❖24G298 none 11:1 none 35 ft.

❖24G299 none 11:1 none 50 ft.

❖24G300 none 11:1 none none

24G301 none 17:1 120 Vac 25 ft.

24G302 none 17:1 120 Vac 35 ft.

24G303 none 17:1 120 Vac 50 ft.


24G305 none 17:1 240 Vac 25 ft.

24G306 none 17:1 240 Vac 35 ft.

24G307 none 17:1 240 Vac 50 ft.


❄24G309 none 17:1 none 25 ft.

❄24G310 none 17:1 none 35 ft.

❄24G311 none 17:1 none 50 ft.

❄24G312 none 17:1 none none

24G313 none 20:1 120 Vac 25 ft.

24G314 none 20:1 120 Vac 35 ft.

24G315 none 20:1 120 Vac 50 ft.


24G317 none 20:1 240 Vac 25 ft.

24G318 none 20:1 240 Vac 35 ft.

24G319 none 20:1 240 Vac 50 ft.


❖24G321 none 20:1 none 25 ft.

❖24G322 none 20:1 none 35 ft.

❖24G323 none 20:1 none 50 ft.

❖24G324 none 20:1 none none

Model MountingPump Ratio Heater

Hose Bundle

c T6

c T4

Warnings

4 3A1195D

WarningsThe 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.

WARNINGWARNINGWARNINGWARNINGFIRE AND EXPLOSION HAZARDFlammable 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.

TOXIC FLUID OR FUMES HAZARDToxic 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.

SKIN INJECTION HAZARD High-pressure fluid from gun, 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.

• Do not spray without trigger guard installed.

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

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

• Follow the Pressure Relief Procedure when you stop spraying 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.

Warnings

3A1195D 5

MOVING PARTS HAZARDMoving 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 HAZARDMisuse 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.

• 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.

PRESSURIZED ALUMINUM PARTS HAZARDUse of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

PERSONAL PROTECTIVE EQUIPMENTYou 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.

WARNINGWARNINGWARNINGWARNING

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information

6 3A1195D

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety InformationMEKP 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 produc-ing the curing reaction of polyester resins and gel-coats also produces the hazards which require great care and caution in its storage, transportation, handling, process-ing and disposal.

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

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

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

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

Continued

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

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

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

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

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

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information

3A1195D 7

Polyester Resins and Gel-Coats

Spraying and Lamination Operations

NOTE: Graco recommends that you consult OSHA Sec-tions 1910.94, 1910.106, 1910.107 and NFPA No. 33, Chapter 16,17, and NFPA No. 91 for further guidance.

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

Read the material manufacturer’s warnings and material MSDSs to know specific hazards and precautions related to polyester resins and gel-coats.

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

Remove all accumulations of overspray, FRP sandings, etc. from the building as they occur. If this waste is allowed to build up, spillage of catalyst is more likely to start a fire.

If cleaning solvents are required, read material manufacture’s warnings and material MSDS to know specific hazards and precautions. (Graco recommends that clean-up solvents be nonflammable.)

Grounding

8 3A1195D

Grounding

1. Attach the grounding clamp assembly (17440-00) to the catalyst pump.

2. Securely attach the grounding clamp assembly (7749-00) to a permanently grounded rod or pipe. Attach the other end of grounding clamp assembly to the catalyst pump.

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.

Air compressor: follow manufacturer’s recommenda-tions.

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.

To maintain grounding continuity when flushing or relieving pressure: hold metal part of the spray gun firmly to the side of a grounded metal pail, then trigger the gun.

The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit.

FIG. 1

FIG. 2: Ground System

Attach grounding clamp

To Catalyst Pump

GroundingRod or Pipe

Installation

3A1195D 9

InstallationNOTE: Completely assemble any mounting option before starting the installation steps.

Tools Required:

All required tools are standard sizes.

• standard wrench and socket set

• standard hex key set

• tape measure

1. Loosen clamp bolts to expose pump mounting bracket. Attach the pump mounting bracket to the air motor. Apply thread sealant to threads and tighten hex bolts using a 3/8 in. hex key.

2. Stand the pump assembly next to the mast, and install the pump mounting bracket.

3. Lift pump mounting bracket with the pump assembly facing the front of the cart as shown. Lift to approxi-mately 36 in. (914.4 mm) from the top of the cart to the top of the pump mounting bracket. Use a 3/4 in. wrench to tighten.

FIG. 3

FIG. 4

Pump mountingbracket

Hex bolts

Clampbolts

FIG. 5

36 in. (914.4 mm)

Installation

10 3A1195D

4. Attach the catalyst pump assembly to the fluid sec-tion plate using the supplied bolts and washers.

5. Attach the catalyst pump drive arm to the pump shaft.

6. Attach the air manifold (24G534 or 24G535) approx-imately 1-2 in. (25.4-50.8 mm) from the top of the air motor to the bottom of the air manifold. Use u-bolts to secure.

FIG. 6

FIG. 7

Bolts and Washers

FIG. 8

1-2 in. (25.4-50.8 mm)

Installation

3A1195D 11

7. Mount the catalyst bottle bracket using the supplied u-bolts. Mount it from the top of the cart to the top of the catalyst bracket (approximately 34 in. (863.6 mm)) and parallel with the material pump

8. Install the catalyst bottle with the elbow fitting facing the front of the system.

9. Install tubing (9704-11) from the catalyst bottle to the inlet fitting on the catalyst pump. Push the tubing into the catalyst bottle supply fitting until it stops. Use two wrenches to carefully tighten the compres-sion nut to lock down the tubing.

NOTE: Cut the tubing so that it provides a natural gravity feed to the catalyst pump.

FIG. 9

34 in. (863.6 mm)

FIG. 10

FIG. 11

Installation

12 3A1195D

10. Install the catalyst and bypass tubing into the cata-lyst bottle cap. Ensure the filter screen is in place under the cap.

11. For 11:1 units, attach a 3/8 in. 90° elbow, from the pump kit, and a 3/8 in. x 3/8 in. fitting from the sys-tem kit.

12. For 17:1 and 20:1 units, replace the 3/4 JIC fitting on the pump with a 3/8 in. x 3/8 in. fitting from the system kit.

FIG. 12

FIG. 13

Elbow

Fitting

Installation

3A1195D 13

System Setup1. Remove the pump inlet safety cap and drain the test

oil into an empty container.

2. Follow Pressure Relief Procedure, page 16, and Flushing, page 17.

3. Attach the bypass hose to the fitting and tighten.

4. Rotate the trigger lock (BE) down to engage it.

5. Attach the catalyst atomizing 1/4 in. OD tubing to the catalyst atomizing inlet fitting (BA).

6. Attach the catalyst (stainless steel) hose to the cata-lyst inlet fitting (BC).

7. Attach the AAC 1/4 in. OD tubing to the AAC inlet fit-ting (BH).

8. Attach the 3/8 in. OD air tubing to the trigger air chop inlet fitting (BB).

9. Attach the resin (blue) hose to the resin inlet fitting (BG).

10. Attach the chopper unit to the fitting (BF). See the RS Spray Gun Instructions-Parts manual for instruc-tions.

FIG. 14

Bypass Valve

FIG. 15: RS Gun Hose Fittings

RS External Mix Chop Gun

BE

r_258970_3A0134_1a

BH

BG

BA

BF

BB

BC

Installation

14 3A1195D

11. If using a boom: Route the hose bundle from the spray gun through the boom as shown. Use the binding straps to secure the hose bundle to the boom. Route the fiberglass roving strands through the roving guides as shown.

To avoid personal injury and/or equipment damage keep the mast secured in the retracted position before transporting the system to prevent the mast from swinging and causing system imbalance.

FIG. 16

Start at this end.

Secure hoses to boom with binding straps.

Route hoses between springs.

Secure hoses to boom withbinding straps.

Start fiberglass roving here.

To Gun

From Spool

Route fiberglass roving strands through theroving break guides as shown.

Installation

3A1195D 15

12. Attach all hoses and tubing as shown. NOTE: The following diagram displays point to point connections only. It does not suggest actual routing of hoses and tubing. Route all hoses and tubing neatly; ensure they are free of any moving components.

FIG. 17

MA

IN A

IR

= A

ir L

ine

s

= C

lea

r Tu

bin

g

= M

ate

ria

l H

os

es

= C

ata

lys

t H

os

e

Air

Ho

se

Ato

miz

e “

Re

d” T

ub

ing

AA

C C

lea

r H

os

e

Ca

taly

st

Ho

se

Fro

m B

oo

m

Ca

taly

st

Bo

ttle

Ma

teri

al

Dru

m

Ma

teri

al

Pu

mp

Re

cir

cu

lati

on

Ho

se

(ta

pe to

geth

er w

ith g

reen

mat

eria

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Do

Not

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rt th

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ses

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ater

ial

drum

unt

il th

e sy

stem

has

bee

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shed

Pic

k-U

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it

Ma

teri

al

Ho

se 3/8

in

. C

lea

r Tu

bin

g

1/8

in

. C

lea

r Tu

bin

g

1/4

in

. C

lea

r Tu

bin

g

Atta

ch C

hop

Hos

e

Setup

16 3A1195D

Setup

Flush Before Using EquipmentThe equipment was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid con-taminating your fluid with oil, flush the equipment with a compatible solvent before using the equipment. See Flushing, page 17.

Pressure Relief Procedure

1. Engage trigger lock.

2. Close the yellow slide valve to bleed off air to the system.

3. Disengage the trigger lock.

4. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure.

5. Engage the trigger lock.

6. Open the ball valve on the catalyst pump to the recirculation position.

7. Open the ball valve on the bottom of the material pump.

8. Have a waste container ready to catch drainage. Leave the ball valves open until you are ready to spray again.

9. If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after follow-ing the steps above, VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Clear hose or tip obstruction.

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

FIG. 18: Close Yellow Slide Valve

FIG. 19: Open Catalyst Pump Ball Valve

FIG. 20: Open Pump Ball Valve

Setup

3A1195D 17

Flushing

NOTE:

• Flush before changing colors, before fluid can dry in the equipment, before storing, and before repairing equipment.

• Flush at the lowest pressure possible. Check con-nectors for leaks and tighten as necessary.

• Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.

1. Follow Pressure Relief Procedure, page 16.

2. Remove spray tip and soak in solvent.

3. Place siphon tube in grounded metal pail containing cleaning fluid.

4. Set pump to lowest possible fluid pressure, and start pump.

5. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun until clean solvent dis-penses.

6. Remove gun from hose. See gun manual to further clean gun.

7. Follow Pressure Relief Procedure, page 16, and Remove fluid filter and soak in solvent. Replace filter cap.

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

Start-up

18 3A1195D

Start-up1. Follow Pressure Relief Procedure, page 16, and

Flushing, page 17.

2. Select a clean, dry air supply.

3. Attach a 3/8 in. or larger air hose to the air manifold inlet.

NOTE: Do not use quick disconnect fitting for attaching air lines. Quick disconnect fittings can severely limit air flow.

4. Ensure system is grounded. See Grounding on page 8.

5. Prepare spray gun for spraying. See RS Spray Gun Instructions-Parts manual for instructions.

6. Open the resin pump recirculation valve.

7. Adjust the resin pump regulator to 20 psi (0.14 MPa, 1.4 bar). The pump will start to slowly cycle.

NOTE: Do not exceed 20 psi (0.14 MPa, 1.4 bar) on the material regulator until a steady material flow is estab-lished.

8. Allow the pump to load. The cycle rate should slow, which indicates the pump is primed.

9. Close the resin pump recirculation valve.

10. Turn and set the atomizing air regulator to 15-20 psi (0.105 - 0.14 MPa, 1.05 - 1.4 bar).

NOTE: Do not exceed Do not exceed 20 psi (0.14 MPa, 1.4 bar) on the material regulator until a steady material flow is established.

FIG. 21

Tighten all fittings before turning on the main air or introducing any material into the system.

Set all valves and regulators to OFF before turning on the main system air to avoid unintended pressurization. Not doing so can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

Main Air

FIG. 22

FIG. 23

Start-up

3A1195D 19

11. Open the ball valve on the spray gun until a steady flow of material is established; then close the valve.

NOTE: Do not exceed 20 psi (0.14 MPa, 1.4 bar) on the material regulator until a steady material flow is estab-lished.

12. Pull and rotate the pivot knob to disengage the cata-lyst pump drive arm. See FIG. 24.

13. Turn the yellow ball valve to the Open/Recirculation position. See FIG. 24.

14. Hand stroke the catalyst pump until a steady stream of catalyst flows back to the bottle. See FIG. 24.

15. Close the yellow ball valve. Hand prime the pump until it reaches 30 (0.21 MPa, 2.1 bar) to 40 psi (0.28 MPa, 2.8 bar). See FIG. 24.

16. Trigger the spray gun into an empty container until all air is purged from the resin side of the system. It may be necessary to hand stroke the catalyst pump several times while the spray gun is triggered to develop a steady stream of catalyst. Let go of the trigger and hand prime the pump again until it reaches 30 (0.21 MPa, 2.1 bar) to 40 psi (0.28 MPa, 2.8 bar).

17. Trigger the spray gun and slowly increase resin pump pressure regulator until a desired spray pat-tern is achieved.

18. Slowly increase air assist air pressure regulator until tails disappear from the spray pattern.

19. Spray a test shot on a clean piece of paper. The shot should be approximately five feet in length. Check the desired gel times and uniformity for cur-ing.

FIG. 24

Yellow Ball

PivotKnob

Valve

PumpArm

FIG. 25: Trigger Spray Gun

FIG. 26: Spray Pattern

no air too little air correct amountof air

Shutdown

20 3A1195D

Shutdown

1. Follow Pressure Relief Procedure, page 16, and Flushing, page 17.

2. Engage the spray gun trigger lock.

3. Push down the yellow slide valve on the air inlet to bleed off air from the system.

4. Turn the catalyst yellow ball valve to the Open/Recir-culation position to relieve pressure.

5. Close the valve. Pressure should be maintained in the resin hose.

6. Service the RS spray gun. Refer to the RS Spray Gun Instructions-Parts manual for service and main-tenance procedures.

NOTICE

Never submerge or soak any spray gun in any type of solvent. Doing so will immediately void the spray gun warranty.

FIG. 27

FIG. 28

Maintenance

3A1195D 21

Maintenance

NOTE: Refer to the RS Gun Instructions-Parts manual for daily maintenance and repair procedures.

1. Follow the Pressure Relief Procedure on page 16.

2. Clean the resin pump filter. Open the pump relief valve to bleed off resin and air pressure form the surge bottle.

3. Inspect and clean the pick-up tube filter.

4. Clean the resin pump wet cup. Refill the wet cup with Graco TSL or a compatible lubricant.

FIG. 29

Fluid FilterAssembly

FIG. 30

FIG. 31: Fill Pump Wet Cup

Filter

Parts

22 3A1195D

Parts

Chop System External Parts

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

Material Spray Nozzles

See the RS Spray Gun Instructions-Parts manual for parts.

Standard Equipment

Part Description

24G502 Catalyst pump assembly24G504 Catalyst pump assemblyGAM-268-01 Material pick-up kit24G395 External chop hose assembly; 25 ft.520563 Air tubing (3/8 in. OD, 28 ft.)24C540 Catalyst hose; 25 ft.24G435 Material hose assembly; 25 ft.24G428 AAC air hose; 25 ft.9704-83 Atomizing air hose (1/4 in. OD, 30 ft.)FM-494 Expandable sleeving (23 ft.)17440-00 Grounding clamp assembly24G534 Air manifold24G535 Air manifold19890-01 Mounting clamp770 / 754-1 / 750-01 Cart mast and boomLPA-165 Catalyst bottleLPA-170 Catalyst bottle bracket▲16D136 Warning and safety label

Pump Options

Part Description

20864-05 Material pump assembly; 11:1 ratio21780-01 Material pump assembly; 17:1 ratio22026-01 Material pump assembly; 20:1 ratio

Parts

3A1195D 23

SSP-175 Safety Guard Kit

SSP-175 Parts

7

10

7

7

10

10

6

107

5

7

7

7

10

10

10

92

9

1

3

4 (Remove protective film from both sides of the safetyglass and attach it to the cover using ref. 7 and 10.)

Ref. Part Description Qty.1 SSP-172 GUARD, surround 12 SSP-173 GUARD, left pump 13 SSP-174 BRACKET, angle 14 SSP-176 GUARD, window 15 SSP-177 GUARD, right pump 16 SSP-178 GUARD, front, right pump 17 20188-16C SCREW 178 7486-05 WASHER, fender 49 7486-13 WASHER 310 7734-06 WASHER, lock 13

Parts

24 3A1195D

LPA-165 Catalyst Bottle LPA-170 Catalyst Bottle Brackett

★ Not shown.

Ref. Part Description Qty.101 LPA-167-1 BOTTLE 1102 LPA-172 SCREEN 1103 LPA-176 CAP 1104 21039-00 ADAPTER, tube 1105 21040-00 ELBOW 1106 21044-01 SEAL 1107 21045-01 NUT, hex 1108 9704-11 TUBE 5

103

106

108

105104107

101

102

Ref. Part Description Qty.110 CP-126 BOLT, u 2112 LPA-169 SUPPORT, bottle 1113★ 7486-07 WASHER 4114 7734-07 WASHER, lock 4

112

114

110

Parts

3A1195D 25

GAM-268-01 Material Pick-up Kit

Filter options:

Ref. Part Description Qty.201 20394-00 TUBE, pick-up 1202 20395-00 FITTING, elbow 1203 20397-01 FILTER, mesh 1204 20398-02 HOSE, material 1

Part Description20397-02 100 mesh filter20397-03 50 mesh filter

203

204202

201

Parts

26 3A1195D

24G534 Air Manifold

r_24

G53

4_3A

1192

_1a

306, 310

322

320 324

305

317

312

316

321

301, 308, 314, 318, 319

307

321

316

306, 313

317, 303

305

309 304

304

321

316

305

306, 311 317325 326 327

323

302321

315

Ref. Part Description Qty.301 CP-126 BOLT, u-bolt 2302 MPB-208 FILTER, air 1303 MPB-209 HOSE 1304 1625-23 PLUG, pipe; 3\8 4305 18199-02 REGULATOR, air; 3/8 npt 3306 18318-02 GAUGE, air, 0-100 psi;1/4 npt 3307 20031-00 BLOCK, manifold 1308 20032-00 BRACKET, manifold 2309 20181-00 LABEL, manifold 1310 20182-00 LABEL, aac, manifold 1311 20183-00 LABEL, atomize 1312 20185-00 LABEL, chopper, manifold 1313 20186-00 LABEL, material 1314 20188-20C SCREW; ss, 0.250-20 x 0.625 4315 21402-00 VALVE, lockout, 3-way; 3/8 npt 1316 3165 VALVE, ball, 2-way; 3/8f, 3/8m

brass3

317 4342-04 FELBOW; 3/8 nptm x 3/8 nptf brass

3

318 7486-07 WASHER, flat, std; 5/16 4319 7734-07 WASHER, lock, spring; 5/16 4320 16G245 FITTING; 3/8 npt x 1/4 npt 1321 8115-03 PIPE, nipple, hex; 3/8 x 3/8 4

322 16G244 FITTING; 3/8 npt x 3/8 tube 1323 9672-12 PIPE, nipple, 3/8 npt x 2 gal 1324 16G246 FITTING;1 /4 npt x 1/8 npt 1325 7596-02 FITTING, pipe, bush; 3/8 x 1 1326 21215-00 VALVE, relief 1327 LPA-143 FITTING, connector 1

Ref. Part Description Qty.

Parts

3A1195D 27

24G535 Air Manifold

r_24G535_3A1192_1a

415

405, 411

423

413

423

419

428

428 401, 406

417403

403

428

428

418

414

423

412, 422, 424

403 407

421

410

427

420

405, 408425431

404

426

426

420

405, 409

421

404

Ref. Part Description Qty.401 CP-126 BOLT, u-bolt 2402 20655-05 ELBOW; 3/8 nptm x 1/4 tube b 1403 1625-23 PLUG, pipe; 3\8 4404 18199-02 REGULATOR, air;3/8 npt 2405 18318-02 GAUGE, air, 0-100 psi;1/4 npt 3406 20032-00 BRACKET, manifold 2407 20181-00 LABEL, manifold 1408 20182-00 LABEL, aac, manifold 1409 20183-00 LABEL, atomize 1410 20185-00 LABEL, hopper, manifold 1411 20186-00 LABEL, material 1412 20188-20C SCREW, bhdc; ss, 0.250-20 x

0.6254

413 21395-00 REGULATOR 1414 21666-00 VALVE, ball, lockout, vented;

3/4f, brass1

415 21733-00 ELBOW; 1/2 nptf x 3/4-16 1417 21736-00 BLOCK, manifold 1418 21737-00 FILTER, air; 1/2 npt 1

419 21739-00 VALVE, ball, 2-way; 1/2 nptf brass

1

420 3165 VALVE, ball, 2-way; 3/8f, 3/8m, brass

2

421 4342-04 ELBOW; 3/8 nptm x 3/8 nptf, brass

1

422 7486-07 WASHER, flat, std; 5/16 4423 7596-04 FITTING, pipe, bush; 3/4 x 1/2 3424 7734-07 WASHER, lock, spring; 5/16 4425 16G245 FITTING; 3/8 npt x 1/4 npt 1426 8115-03 PIPE, nipple, hex; 3/8 x 3/8 2427 16G244 FITTING; 3/8 npt x 3/8 tube 1428 8115-07 PIPE, nipple, hex; 1/2 x 1/2 4429 8560-05 FITTING, connector 1431 16G246 FITTING; 1/4 npt x 1/8 npt 1

Ref. Part Description Qty.

Parts

28 3A1195D

21460-00 Heater Conversion Kit

614

613

619

610

605

618

611

606

617

620

609

615

Inle

t60

7

615

604

616

603

602

608

612

609

Out

let

Hea

t ins

ulat

or (

1670

02);

supp

lied

with

hea

ter

Parts

3A1195D 29

21460-00 Heater Conversion Kit Continued

601

Inlet

Outlet

20195-25 (part of hose assy. to spray gun)

20262-00 (part of tank assy. back to tank)

Ref. Part Description Qty.601 D-156-04 HOSE, assy. 1602 RM-850-02 FITTING, pipe, tee; 3/8 1603 14626-00 FITTING; 3/8 npt x 3/8 nps 2604 14626-01 FITTING; 3/8 npt x 1/4 npsm 2605 19891-00 CLAMP, pipe, set 2606 19892-00 PLATE, cover, clamp 2607 20027-00 ELBOW; 1/2 nptm x 1/2 nptf cp 1608 226819 HEATER, Viscon; 240 V 1609 21192-00 VALVE, ball, 2-way; 3/8 1610 GCC470 PLATE, heater, mounting 1611 100338 NUT, jam 4612 4342-23 ELBOW; 3/8 nptm x 3/8 nptf zp 1613 7734-10 WASHER, lock, spring; 1/2 4614 8155-160C SCREW, hex head; CS,

0.500-13 x 5.000 zp4

615 8462-15 FITTING, pipe, nipple, hex; 1/2 x 3/8 npt

2

616 8462-17 FITTING, pipe, nipple, hex; 3/8 x 3/8 npt

1

617 112248 NUT, hex 4618 105510 WASHER, lock, spring. hi-collar 4619 110755 WASHER, plain 8620 114238 SCREW, cap, hex head 4

Technical Data

30 3A1195D

Technical Data

Maximum fluid working pressure (11:1 models) . . . . . . 1300 psi (9 MPa, 90 bar)



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

Typical flow rate of spray gun . . . . . . . . . . . . . . . . . . . . Refer to RS Spray Gun manual

Maximum fluid temperature . . . . . . . . . . . . . . . . . . . . . . 100° F (38° C)

A component (catalyst) inlet size. . . . . . . . . . . . . . . . . . 1/4 in. tube

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

Sound pressure (11:1 models) . . . . . . . . . . . . . . . . . . . 84.83 dB(A)



Sound power, measured per ISO 9614-2 (11:1 models) 87.04 dB(A)



System dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 in. L x 53 in. W x 90 in. H (1219.2 mm L x1346.2 mm W x 2286.0 mm H)

Boom dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully extends to 155 in. (3937 mm) L

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 lbs (98 kg)

Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalyst: chemically coated aluminum, stainless steel, chemically resistant o-ringsResin: carbon steel, carbide, chemically resistant o-rings

Technical Data

3A1195D 31

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 3A1195

Graco Headquarters: MinneapolisInternational Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

Copyright 2010, Graco Inc. is registered to ISO 9001www.graco.comRevised 03/2011

Graco Standard WarrantyGraco 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 CUSTOMERSThe 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 InformationFor 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

Documents

GlasCraft Chop System External...Warnings 4 3A1195D Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point