ROYAL Cyclone 1 Extruder Operators Instruction Manual Read and understand the instructions in this Manual before using this machine! Keep this Manual with the Cyclone Extruder at all times. It is the Cyclone Extruder owner s responsibility to ensure that all of the workers using this machine are thoroughly trained. Provide workers with this Operator s Manual. Make sure they understand its' contents. Read it to them if necessary. Letting poorly trained workers use this machine can result in property or machine damage and/or serious injury or death to personnel. Garlock provides this Operator s Manual at the time of sale as a tool to help instruct the owner/worker in the proper use of the Extruder. ROYAL/Garlock expects the reseller and owner/worker to make every effort to educate themselves in the safe and responsible use of this Extruder before putting this machine into service. WARNING! THIS MACHINE IS DESIGNED FOR USE ON FLAT, LEVEL ROOFS ONLY. P/N 161385 Rev 9/14
Thank you for purchasing this ROYAL/Garlock product. With proper use and care, the ROYAL Cyclone will serve you for many years. For the safety of the operator and other people on the jobsite, it is imperative that all operators of this machine read and understand the contents of this instruction manual before using this machine. Date of Purchase Serial Number INTENDED USE: This machine is intended for the sole purpose of mixing and applying adhesives to roof substrates. WARNING TO EQUIPMENT OWNER! Before beginning work on the roof, install OSHA approved Perimeter Guarding Systems around all roof edges and openings. This includes all Skylights (whether they are left in place or removed) and any Roof Hatches which are left open or have been removed. It is against Federal Law to leave these areas unguarded and will result in fines against the Contractor if any unguarded openings are on the roof. In the event of injury or death of a worker due to falling from an unguarded edge or through an unguarded opening, legal prosecution may be brought against the Contractor, Equipment Owner and Building Owner. WARNING! Working at or near the roof edge is dangerous and can subject the Worker to serious injury or death from falls. The Roofing Contractor and the Worker must make every effort to ensure the area where he/she will be working is as safe as possible. This means taking only the tools you need to the roof edge, removing all trip hazards and loose material, the wearing and proper use of OSHA approved Harnesses and Life-Lines, making no sudden or unplanned moves and being constantly aware of your surroundings and position/location relative to the roof edge. OPERATOR PREPARATION: Recommended Tools for Maintenance. Allen Wrench set. 2 Adjustable Wrenches Basic English Wrench set Cyclone Flushing Solution (2 boxes minimum) Wear Proper Clothing. Wear Safety Glasses and protective clothing if any cutting, scraping, or sweeping is being done in your work area. Wear Safety Shoes. Hard Hat must be worn by Operator when work is being done overhead. 2
General Safety Information The information in this manual must be understood and followed to insure safe, productive operation of your Cyclone 1 Extruder. As with all mechanical equipment, safety precautions must be taken when this equipment is being used or serviced. Failure to follow the guidelines listed in this manual and/or failure to use common sense may result in bodily injury and/or damage to equipment and property. PROTECTIVE EQUIPMENT: Protective equipment such as safety glasses and protective gloves must be worn when operating or servicing the Cyclone 1 Extruder. Follow guidelines and recommendations of material manufacturer. Consult your local OSHA office regarding respirator requirements. ACCEPTABLE USE: The Cyclone 1 Extruder is designed for the dispensing of plural component urethane foams and adhesive systems. Under no circumstances should any acid or corrosive chemicals be used in this machine. Likewise, Petroleum based products or solvents will damage the Pumping System and must not be used. Use only products that have been supplied or approved by ROYAL/Millennium Corp. The electrical circuitry of the Cyclone 1 Extruder is not of explosion proof design and should not be used in any environment requiring such a design. EQUIPMENT PRECAUTIONS: The Cyclone 1 Extruder runs on 110 Volt 60 Hz AC Current. Use a 3-wire power cord that is in good condition, rated for outdoor use and a minimum of 14-gauge construction. Servicing electrical components should only be done by trained personnel and only after disconnecting power to the equipment. 3
1. OPERATING INSTRUCTIONS: Read and understand all instructions before using your Cyclone 1 Extruder. Failure to follow all instructions may result in electrical shock, fire, and/or serious injury. These instructions cannot cover all situations and conditions that may occur so caution and common sense must be employed by the user at all times. TO PREVENT MATERIAL CROSSOVERS IN THE GUN AND HOSES: The Static Mixing Tips are disposable and should be removed from the Gun assembly during any pause in application. Pausing for as little as 30 seconds in hot conditions may allow reacting material to move back into the Gun and Hose. During the attachment and removal of Static Mixing Tips, a Pliers may be necessary to turn the Tip Retaining Nut. Be sure the Static Mixing Tip is fully seated on the Nozzle. Keeping the threads on the Gun clean with solvent allows Tip Retaining Nut to be tightened completely. WARNING! This machine pumps caustic material at significant pressure. When opening Gun make sure it is not pointed at yourself, another person or any surface to which you do not intend to apply material. 2. START UP: Make sure Gun is in the SHUT mode and Motor is OFF. Material temperature must be 70 degrees F minimum before use. 1. Place Box marked Part 1 in side of Tray marked 1 2. Place Box marked Part 2 in side of Tray marked 2 3. Apply Grease to Fittings on Hoses from Pumps before connecting them to Boxes. 4. Fittings must match by color: Black to Black (Part 1) and Gray to Gray (Part 2) 5. With Gun Valves closed, plug Power Cord into a grounded outlet or extension cord. The Cord must be a minimum 14/3 construction and not to exceed 100 ft in length. 6. Turn Power Switch ON. Motor will run for up to 1.5 minutes, then it will shut off automatically. This is normal. Do not flip Power Switch again. Motor will restart when you open the Gun Valves. 7. SLOWLY open Gun Valves, dispense a small amount of chemical into a waste container. 8. Confirm that Parts 1 and 2 dispense evenly. Close Gun and install a Static Mixing Tip. 9. Open valves and dispense adhesive directly to the substrate as recommended by the chemical manufacturer. 4
3. SHUTTING DOWN OR DURING EXTENDED BREAKS: IMPORTANT! Remove Static Mixing Tip during any pause in application or operation. If Static Mixing Tip remains on the Gun, material will react and harden in the end of the Gun and possibly the Hoses. 1. Close Gun valve. 2. Turn off Pump by flipping Power Switch to the OFF position. 3. Remove Static Mixing Tip and discard. 4. Place Tip Retaining Nut in solvent. If you are using a disposable plastic nut, simply discard it and use a new one. 5. Relieve any pressure in Hoses by opening and closing Gun valve. 6. Apply grease to Gun through grease fittings on the top of the Gun until it flows out of the threaded end on Manifold. Pump grease into the Part 1 fitting first. IMPORTANT! Moisture from the air reacts with Part 1 (isocyanate) causing it to gel and harden. Any Part 1 that is not to be used immediately must be sealed and kept from absorbing moisture from air. 4. STORING THE CYCLONE 1 EXTRUDER: Long-term storage requires that Parts 1 and 2 be flushed from the lines and Pumps using Cyclone System Solution Solvent. After storage, the Gravity Feed Lines may need to be replaced. Gravity Feed Hoses and Hoses to Gun may be easily replaced if damaged during use or after improper shutdown or storage. Chemical can be allowed to stand in the machine for short periods of time while not in use. It is very important that the isocyanate (Part 1) not be exposed to air or moisture. Some Cyclone System Solution Solvent should be run through the pump and hoses every three to four weeks when the pump is not in use. 5. MAINTAINANCE TIPS: All pathways through the Gun Manifold are 3/16 in diameter and can be cleaned with a hand-held 3/16 diameter drill bit. Take care not to damage ports with bit. 5
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Large Replacement Parts: Front Tire 140521 Caster 140459 Hose-Part 1 (Blue) Hose-Part 2 (Black) 30 FT 172314 30 FT 172568 3 FT 172316 3 FT 172569 Hose (from Pump to Boxes) 153332 Fitting-Black (Part 1) 155196 Fitting-Gray (Part 2) 155197 Grease Gun-Pistol Grip 155212 Grease Tube 14 OZ 155213 Hose Clamp 152158 Coupling Guard 426685S 7
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Symptom Check Solution Motor clicks on and off frequently. 1. Leaking at threaded joints on Part 2 side. 1. Tighten joints where needed. Motor will not start when valves are opened. 2. Check Valve not seating properly. 2. Remove and clean or replace Check Valve. 1. Circuit Breaker beneath electrical box or Power Switch not switched to "ON" 1. Flip Circuit Breaker and/or Power Switch to "ON" 2. Clogged Manifold or Mixing Tip. 2. Clean Manifold or change Mixing Tip 3. Check Motor wiring for loose connections. TO BE DONE BY A QUALIFIED ELECTRICIAN! 3. Fix loose connection(s). If connections are good, Motor may be burned out. Replace. Motor continues to run when valves are closed. 1. Faulty Pressure Switch 1. Replace Switch. Order Parts Kit 408254 Leaky Quick Connect Fittings where Inlet Hose connects to bottom of Bladder. 1. Worn or broken Quick Connect Fitting. 1. Replace Quick Connect Fitting 2. Misalignment of Bag in Tray. 2. Move Bag to achieve better alignment and remove any side load on Fitting. 3. Hose Clamp not tight. 3. Tighten Clamp. Do not crush Hose. 4. End of Inlet Hose worn, cracked or brittle. 4. Replace Inlet Hose Unequal amounts of Adhesive are being used 1. Leaky Quick Connect Fitting 1. Replace Quick Connect Fitting 2. Inlet hose collapsed 2. Replace inlet hose 3. Check adhesive flow at end of manifold. Remove mixing tip / Place equal-sized containers (coffee cup, jar, bottle..etc.) under each stream of the manifold for 10-15 seconds. Both containers should have equal volumes; if not, check for leaks and blockages. Consult with manufacturer if problem continues. 3. Clear blockage / replace clogged, warn or broken components Royal Cyclone Troubleshooting Guide 161514 9
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