2120 COMMANDER SPRAYER OPERATOR S INSTRUCTION MANUAL

Transcription

1 2120 COMMANDER SPRAYER OPERATOR S INSTRUCTION MANUAL WARNING: Serious injury may result if this product is misused. The manufacturer provides the following instructions for use and care of this equipment and relies upon the purchaser to see to it that these instructions are made clear to the person who will be using the equipment. Reciba entrenamiento y entienda el manual de instrucciones, o haga que le lean el manual, antes de operar esta unidad. Part Number: Revised: 3/6/ NIAGARALANE, PLYMOUTH, MN Phone: (763) Fax (763)

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3 3 TABLE OF CONTENTS 2120 COMMANDER SPRAYER SPRAYER SPECIFICATIONS... 5 SAFETY PRECAUTIONS... 6 DO NOT OPERATE BEFORE READING... 6 SAFETY WARNINGS... 8 MEDICAL ALERT AIRLESS SPRAY WOUNDS... 8 SPRAY TIP SAFETY... 8 SPRAY GUN SAFETY DEVICES... 8 TIP GUARD... 8 GROUNDING... 9 MOVING PARTS HAZARD... 9 FLUID AND SOLVENT COMPATABILITY... 9 HOSE SAFETY... 9 SETUP AND OPERATION OPERATION STARTING THE SPRAYER PRIMING THE PUMP ADJUSTING THE PRESSURE SHUTTING DOWN THE SPRAYER PRESSURE RELIEF PROCEDURE FLUSHING GUIDELINES CONTROLS HYDRAULIC TANK PUMP COMPONENTS FLUSHING PROCEDURE MAINTENANCE MAJOR COMPONENTS PUMP HEAD ASSEMBLY HYDRAULIC TANK ASSEMBLY CONTROL PANEL OIL PUMP ASSEMBLY MISCELLANEOUS HOSES MISCELLANEOUS PARTS DISPLACEMENT PUMP ( GRACO) MAJOR COMPONENTS (PRE-2012) PUMP HEAD ASSEMBLY (PRE-2012) CONTROL PANEL (PRE-2012) MISCELLANEOUS PARTS (PRE-2012) NOTES MAIL IN WARRANTY CARD AND CERTIFICATE UPDATE YOUR INSTRUCTIONS AND DECALS... 36

4 COMMANDER SPRAYER Thank you for purchasing this quality Garlock product. With proper use and care, this product will serve you for years. For the safety of the operator and other people on the job site, it is imperative that the operator read and understand these instructions before using. DATE OF PURCHASE SERIAL NUMBER

5 SPRAYER SPECIFICATIONS Length mm Width mm Height mm Height Extended mm Lift Distance mm Weight (w/fluids) 750 Lbs. 340 Kg. Wheels Front 18 x 8.5 x 8 x 1 4 PLY 18 x 8.5 x 8 x 1 4 PLY Wheels Rear 4.1 x 3.5 x 4 4 PLY 4.1 x 3.5 x 4 4 PLY Gas Tank Capacity 6.5 Gallons 24.6 L. Hydraulic Fluid Conoco MV32 Conoco MV32 Hydraulic Capacity 15 Gallons 56.8 L. Hydraulic Pump Piston-Pressure Compensated w/ Remote Control Piston-Pressure Compensated w/ Remote Control Engine Kohler 18 H.P. O.H.C. O.H.V. Electric Start Kohler 18 H.P. O.H.C. O.H.V. Electric Start Charging System 15 Amp. 15 Amp. Material Pump Graco Model Graco Model Max. Pressure 4500 P.S.I Atm.

6 6 Safety Precautions Do Not Operate Before Reading INTENDED USE: This machine is intended to be used for the sole purpose of spraying mastics on flat, level roofs. Any other use of this equipment voids the manufacturer's warranty and is the sole responsibility of the owner/user, should damage or injury occur. For use on flat, level roofs only. Keep other people clear of machine during operation. Do not operate without a perimeter warning line system. Do not operate within ten feet of roof edge (or within six feet if operating parallel to edge). Guard all openings in the roof. Do not operate the machine if it is damaged. Repairs must be made by a qualified mechanic. Replace damaged components. Do not modify the machine. Do not operate a machine that has been modified. Wear proper attire: Long sleeve cotton shirt, buttoned at the cuff, long pants without cuffs, gloves (cotton or leather) that cover your wrist and fit snug at cuff, and high top safety shoes. Keep the equipment in good operating condition. Avoid slick areas on the roof to prevent slipping. Do not operate this machine if you are under the influence of alcohol, marijuana, or drugs that could impair judgment and ability. The owner or operator must see that all warning decals are in place and legible. Write to Garlock Equipment Co. for replacement decals and instructions if needed. Operator must be trained to do the specific job before operating equipment on an actual job. Do not exceed weight carrying capacity of the deck. Check with owner or architect for deck capacity.

7 7 The following information is quoted from OSHA: Safety and Health Standards Digest, OSHA 2202 revised September It is usually a good idea for the employer to keep a record of all safety and health training. Records can provide evidence of the employer's good faith and compliance with OSHA standards. Documentation can also supply an answer to one of the first questions an accident investigator will ask: "Was the injured party trained to do the job?" Training in the proper performance of a job is time and money well spent and the employer might regard it as an investment rather than an expense. An effective program of safety and health training for workers can result in fewer accidents and illnesses, better morale and lower insurance premiums and other benefits. Readers with questions concerning worker safety and health training should contact their regional OSHA office.

8 8 SAFETY WARNINGS HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY. FOR PROFESSIONAL USE ONLY OBSERVE ALL WARNINGS READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE OPERATING EQUIPMENT FLUID INJECTION HAZARD GENERAL SAFETY This equipment generates very high fluid pressure.spray from the gun; leaks or ruptured components can inject fluid through your skin and into your body and cause extremely serious bodily injury, including the need for amputation. Also fluid injected or splashed into the eyes or on the skin can cause serious injury. NEVER point the spray gun at anyone or at any part of the body. NEVER put hand or fingers over the spray area. ALWAYS have the tip guard on the spray gun when spraying. ALWAYS follow the PRESSURE RELIEF PROCEDURE before cleaning any system equipment. NEVER try to stop or deflect leaks with your hand or body. BE SURE equipment safety devices are operating properly before each use. MEDICAL ALERT AIRLESS SPRAY WOUNDS If any fluid appears to penetrate your skin get EMERGENCY MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT. Tell the doctor or nurse exactly what fluid was injected. SPRAY TIP SAFETY Use extreme caution when cleaning or changing tips. If the tip clogs while spraying, reverse the tip and trigger the gun to blow out the clog. NEVER WIPE OFF BUILD UPAROUND THE SPRAY TIP UNTIL PRESSURE IS FULLY RELIEVED SPRAY GUN SAFETY DEVICES Be sure all gun safety devices are operating properly before use. Do not remove or modify any part of the gun as this can cause a malfunction and result in serious bodily injury. TIP GUARD ALWAYS have the tip guard in place on the gun while spraying. The tip guard alerts you to the fluid injection hazard and helps to reduce, but does not prevent, the risk of accidentally placing your fingers or any part of your body close to the spray tip.

9 9 GROUNDING To reduce the risk of static sparking, ground the sprayer and all other spray equipment used or located in the spray area. MOVING PARTS HAZARD KEEP CLEAR of moving parts when starting or operating the sprayer. Follow the pressure relief procedure before checking or servicing sprayer to prevent it from starting accidentally. GENERAL SAFETY Misuse of the equipment or accessories, such as incompatible chemicals and fluids or worn or damaged parts can cause them to rupture. NEVER alter or modify any part of this equipment. Doing so could cause it to malfunction. CHECK all spray equipment regularly and repair or replace worn or damaged parts immediately. ALWAYS WEAR PROTECTIVE EYEWEAR, GLOVES, CLOTHINGANS RESPIRATOR AS RECOMMENDED BY THE FLUID AND SOLVENT MANUFACTURER FLUID AND SOLVENT COMPATABILITY BE SURE all fluids and solvents are chemically compatible with the wetted parts of this pump. Always read the fluid and solvent manufacturers literature before using in this sprayer. Do not use 1,1,1-trichloroethane, methylene chloride, or other halogenated hydrocarbon solvents of fluids containing such solvents in this equipment, which contains aluminum and /or zinc parts. Such use could result in a serious chemical reaction, with the possibility of explosion. HOSE SAFETY High-pressure fluid in the hoses can be very dangerous. If the hose develops a leak, split or rupture due to any kind of wear, damage or misuse, replace it immediately. NEVER try to mend a hose with tape or other device. A repaired hose cannot contain the high-pressure fluid.

10 10 SETUP AND OPERATION 1. CONNECT THE HOSES AND GUN Do not install the tip yet 2. FILLTHE PACKING CUP wet cup 1/3 full of throat seal liquid or a lightweight oil 3. CHECK THE HYDRAULIC FLUID LEVEL. Refer to the sight gauge on the hydraulic tank If necessary remove the filler cap and add fluid to the tank. 4. CHECK THE ENGINE OIL Remove the dipstick and check the level. REFER TO ENGINE OWNERS MANUAL FOR MORE INFORMATION RECOMMENDED ENGINE OIL: USE A HIGH QUALITY DETERGENT OIL CLASSI FIED SG OR SH SAE 10W-30 CAPACITY 1.5 QUARTS CHANGE OIL AFTER EVERY 100 HOURS OF OPERATION REPLACE OIL FILTER AFTER 100 HOURS AND AT LEAST EVERY OTHER OIL CHANGE. 5. FILL THE FUEL TANK- USE UNLEADED REGULAR GASOLINE WITH AN OCTANE RATING OF 87 OR BETTER WARNING: FUEL SPILLED ON HOT SURFACES CAN CAUSE FIRE OR EXPLO- SION. ALWAYS SHUT OFF ENGINE AND ALLOW TO COOL BEFORE FILLING THE TANK. FUEL TANK CAPACITY 6.5 GALLONS APPROXIMATE RUN TIME 7 HOURS WHEN FILLED

11 11 Operation 1. PREPARE THE MATERIAL TO BE SPRAYED ACCORDING TO THE MANUFACTURERS RECOMMENDATIONS 2. FOLLOW THE SETUP PROCEDURE AS PREVIOUSLY DESCRIBED 3. STARTING THE SPRAYER: A. Open the bypass valve when starting the sprayer B. Turn the pressure control knob counter-clockwise to the lowest pressure setting C. Pull the choke lever out to choke the engine D. Set the throttle at the halfway point E. Turn the key to the START position until it starts and release to the ON position F. Slowly push the choke lever in as engine warms up NOTE: IN COLD WEATHER RUN THE ENGINE FOR ABOUT 15 MINUTES WITH THE BYPASS VALVE OPEN BEFORE STARTING THE PUMP TO AVOID HYDRAULIC STALLING. 1. PRIMING THE PUMP A. Connect the hoses and the spray gun B. DO NOT INSTALL THE SPRAY TIP UNTIL PRIMED C. Start the engine as described D. Using the hydraulic lift raise the pump over the barrel E. Slowly lower the pump into the barrel F. Open the priming/ pressure relief valve at the pump outlet G. Turn the bypass lever to start the material pump H. Slowly turn the pressure control knob clockwise to increase hydraulic pressure and the material pump will start pumping I. When material comes through the valve, close it J. WITH THE TIP OFF, trigger the gun and hold it over a scrap container. This will allow any debris to be pushed through the lines and out of the system. K. Screw the tip into the gun. 2. ADJUSTING THE PRESSURE A. Turn the pressure control knob clockwise to increase the pressure and counterclockwise to decrease. Tighten the locking ring to set. B. Use the lowest pressure necessary to completely atomize the fluid. Excess pressure will cause over spray. C. If more coverage is needed, use a larger tip. D. Check the spray pattern. The tip and pressure determine the width and flow rate.

12 12 Operation 1. SHUTTING DOWN THE SPRAYER A. Whenever the sprayer is not being used, even for a short time, follow the PRESSURE RELIEF PROCEDURE. B. Clean the tip and gun. C. If flushing is necessary follow the FLUSHING GUIDELINES. D. For long term shutdown or storage, always fill the sprayer with mineral spirits to prevent pump corrosion. NEVER STORE WATER OR WATER BASED MATERIALS IN PUMP FOR LONG PERIODS OF TIME. PRESURE RELIEF PROCEDURE TO REDUCE THE RISK OF SERIOUS BODILY INJURY, INCLUDING FLUID INJECTION, SPLASHING FLUID OR SOLVENT IN THE EYES OR ON THE SKIN, OR INJURY FROM MOVING PARTS OR SHOCK, FOLLOW THIS PROCEDURE WHENEVER THE SPRAYER IS CHEKED OR SERVICED OR SHUT OFF. 1. Open the bypass valve to stop the pump. 2. Turn the engine off 3. Hold a metal part of the spray gun firmly to the side of a grounded metal barrel or pail and trigger the gun to relieve pressure. 4. Open the priming/ pressure drain valve with a container ready to catch the drainage. DO NOT USE VALVE TO RELIEVE MAIN PRESSURE. SERIOUS INJURY MAY RESULT. Leave the valve open until ready to spray again. DO NOT LEAVE OPEN OVERNIGHT OR LONG PERIODS OF TIME.

13 13 Operation RECOMMENDED PROCEDURE FOR SHUTTING DOWN THE SPRAY UNIT OVER NIGHT OR WEEKEND 1. Open the by pass valve to shut off the pump 2. Remove the pump from the material and clean the outside of the intake pipe and suction screen. Lower the unit into a pail of solvent compatible to the material being sprayed or cover the material and pump to keep the air out. 3. Turn off the engine 4. Reverse the tip or remove from the gun trigger the gun to release the pressure from the line. Replace the tip and cover the gun or place the end of the gun in a pail of solvent. IN COLD WEATHER FLUSHING THE PUMP IS RECOMMENDED. FOLLOW THE SAME STEPS FOR SHUTTING DOWN WHILE LEAVING THE SOLVENT IN THE LINE AND PUMP. REMEMBER TO START UP WITH THE TIP OFF THE GUN WHILE PRIMING THE SYS- TEM WHITH MATERIAL. FLUSHING GUIDELINES WHEN TO FLUSH DAILY FLUSHING IS REQUIRED IF USING A TWO PART MATERIAL, WATER BASED MATERIAL IF FREEZING MAY OCCUR AND WHEN SPRAYING PRESSURE SENSITIVE MATERIALS 1. NEW SPRAYER. Your new 2120 SPRAYER was factory tested with oil. The oil was left in the pump to protect parts from corrosion. BEFORE USING OIL BASED MATERIAL FLUSH WITH MINERAL SPIRITS ONLY BEFORE USING WATER BASED MATERIAL FLUSH WITH MINERAL SPIRITS FOL- LOWED WITH SOAPY WATER AND THEN A CLEAN WATER FLUSH. 2. CHANGING MATERIAL - Flush with a compatible solvent (mineral spirits) 3. CHANGING FROM WATER BASE TO OIL BASE. Flush with soapy water and mineral spirits 4. CHANGING FROM OIL BASE TO WATER BASE Flush with mineral spirits followed by soapy water and a clean flush

14 14 Controls THROTTLE LEVER (PRE-2012) PUMP LIFT LEVER GAS CAP/ GAUGE CHOKE KNOB (PRE-2012) CHARGING GAUGE (PRE-2012) IGNITION SWITCH (PRE-2012) PUMP BYPASS VALVE PRESSURE GAUGE PRESSURE ADJUSTING KNOB

15 15 HYDRAULIC TANK HYDRAULIC FILLER CAP HYDRAULIC SIGHT GAUGE HYDRAULIC PISTON PUMP

16 16 PUMP COMPONENTS PUMP RESET BUTTON LOCKING LEVER PRIMING VALVE MATERIAL PUMP

17 17 HOW TO FLUSH FLUSHING PROCEDURE WARNING: FOLLOW THE PRESSURE RELIEF PROCEDURE BEFORE FLUSHING 1. Remove the tip from the gun 2. Pour enough clean compatible solvent into a large empty grounded pail to fill the pump and hoses. 3. Place a pail under the pump. Lower the pump into the solvent pail 4. Turn the pressure control knob counterclockwise to lowest pressure setting 5. Open the priming valve, use a pail to catch the material and solvent. Close the valve when the solvent comes through. 6. Point the gun into the pail; trigger the gun to push material out of the lines. When solvent appears release the trigger. 7. Point the gun into the solvent pail, trigger the gun and circulate the solvent until the system is completely flushed. 8. Release the trigger. BE SURE TO FOLLOW THE PRESSURE RELIEF PROCEDURE AF- TER COMPLETION OF FLUSHING. DO NOT LEAVE PRESSURE IN THE SYSTEM WHEN SHUT DOWN

18 18 MAINTENANCE 1. Keep the material pump packing nut-wet cup 1/3 full of throat seal liquid or light- weight oil at all times. This provides lubrication to the packing 2. When stopping the pump try to stop the pump at the bottom of the stroke. This helps keep the fluid from drying on the rod and damaging the packing. 3. Check the tightness of the packing daily. The nut should be hand tight. Do not overtighten as this adds more friction to the pump. 4. Check the hydraulic fluid daily. Add if necessary 5. Check the engine oil daily. Add if necessary 6. Replace the return line filter every hors of use. 7. Change the hydraulic fluid after 2000 hours of use or annually. For continuous operation in high outside temperature change the fluid more frequently. CHANGING THE HYDRAULIC FLUID A. FOLLOW THE PRESSURE RELIEF PROCEDURE B. Place a container under the hydraulic tank. Remove the drain plug and drain the tank. C. Remove the filter element from the in tank filter. D. Fill the reservoir with hydraulic oil. E. Run the pump unit and check level again. Fill as necessary HYDRAULIC FLUID CONOCO MV32

19 19 MAJOR COMPONENTS

20 20 PUMP HEAD ASSEMBLY

21 HYDRAULIC TANK ASSEMBLY 21

22 22 CONTROL PANEL

23 OIL PUMP ASSEMBLY 23

24 24 MISCELLANEOUS HOSES

25 MISCELLANEOUS PARTS 25

26 26 DISPLACEMENT PUMP (GRACO) ASSEMBLY (45:1)

27 27 DISPLACEMENT PUMP (GARLOCK P/N ) ASSEMBLY (45:1) (AFTER 3/1/2001)

28 28 MAJOR COMPONENTS PRE-2012

29 29 PUMP HEAD ASSEMBLY PRE-2012

30 30 CONTROL PANEL PRE-2012

31 31 MISCELLANEOUS PARTS PRE-2012

32 32 NOTES

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36 To replace any Warning Decals on your Commander Sprayer, simply tear off the bottom half of this page and mail or fax to Garlock Equipment Company for FREE REPLACEMENTS. Address: Fax: Garlock Equipment Co Niagara Lane Plymouth, MN Attention: Sales Dept.