Graco ToughTek MP-Series User manual

3A4349B
EN
Operation
ToughTek
®
MP-Series Mixing Pumps
Electric mixing pump for water-based cementitious materials. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
See Page 2 for model information.
Maximum Working Pressure: 300 psi ( 2.07 MPa, 20.7 bar)
Important Safety Instructions
Read all warnings and instructions in this and all
related manuals. Save these instructions.
WLD

23A4349B
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . 5
MP-20 and MP-40 Series . . . . . . . . . . . . . . . . . . . . . . . 5
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Box Control Panel . . . . . . . . . . . . . . . . . . . . . . 6
Water Pressure Over-ride Plug (OP) . . . . . . . . . . . . . . 7
Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Priming with Water . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pump Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . 12
Prime with Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 15
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Winterizing and Extended Storage . . . . . . . . . . . . . . . 18
Startup After Extended Storage . . . . . . . . . . . . . . . . . 18
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rotor/Stator Pump Repair . . . . . . . . . . . . . . . . . . . . . . 22
Motor Seal Replacement . . . . . . . . . . . . . . . . . . . . . . 23
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MP-20 and MP-40 Series Parts. . . . . . . . . . . . . . . . . . 24
MP-20 and MP-40 Parts List . . . . . . . . . . . . . . . . . . . 25
MP-20 and MP-40 Series Parts (continued) . . . . . . . . 26
MP-20 and MP-40 Parts List (continued) . . . . . . . . . . 27
Water Control Assembly (Ref. 3) . . . . . . . . . . . . . . . . 28
Water Control Assembly Parts List . . . . . . . . . . . . . . . 29
Water Pump Assembly (Ref. 4) . . . . . . . . . . . . . . . . . 30
Water Pump Assembly Parts List (continued) . . . . . . 31
Drive Shaft (Ref. 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Motor Assemblies (Ref. 10) . . . . . . . . . . . . . . . . . . . . 33
Power Cable (Ref. 56) . . . . . . . . . . . . . . . . . . . . . . . . 36
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Electrical Enclosure (Ref. 2) Parts . . . . . . . . . . . . . . . 38
Electrical Enclosure Parts List . . . . . . . . . . . . . . . . . . 39
Systems and Accessories . . . . . . . . . . . . . . . . . . . . . . . 40
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rotor/Stator Pump Kits . . . . . . . . . . . . . . . . . . . . . . . . 41
Nozzle Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Motor Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Drive Shaft Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Water Pump System Kits . . . . . . . . . . . . . . . . . . . . . . 42
Enclosure Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Wheels and Casters Kits . . . . . . . . . . . . . . . . . . . . . . 42
Dimensions (for all models) . . . . . . . . . . . . . . . . . . . . . . 43
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 44
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . 48
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Models
Related Manuals
Manuals are available at www.graco.com
Model Part Description Power
MP-20 25M060 ToughTek MP-20 200-240 VAC, 1 Phase, 60 Hz
25M061 ToughTek MP-20 16A 200-240 VAC, 1 Phase, 50 Hz
MP-40 25M062 ToughTek MP-40 200-240 VAC, 3 Phase, 60 Hz
25M063 ToughTek MP-40 350-415 VAC, 3 Phase, 50 Hz
Manual Description
3A4351 Browning Mortar Applicator Gun
3A4352 Deco Mortar Applicator Gun

Warnings
3A4349B 3
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 or on warning labels, 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
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 equip-
ment, follow the Pressure Relief Procedure and disconnect all power sources.
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 before servicing equipment.
• Connect only to grounded electrical outlets.
• Ensure ground prongs are intact.
• Do not expose to rain. Store indoors.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.

Warnings
43A4349B
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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifi-
cations in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request Safety Data Sheets (SDSs) 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 man-
ufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and cre-
ate safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• 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 EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause
serious injury.
•Relieve Pressure when you stop spraying/dispensing and before cleaning, checking, or servicing
equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
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 Safety Data Sheets (SDSs) 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
Wear appropriate protective equipment when in the work area to help prevent serious injury, includ-
ing eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective 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.
WARNING

Component Identification
3A4349B 5
Component Identification
MP-20 and MP-40 Series
WLD
H
D
L
FRS
C
EJ
M
K
Q
P
GN
%
$
Ref. Description
A Pressure Test Hose
B Power Cable
C Motor Cable
D Drive/Mix Shaft
E Gear Box Motor
F Rotor/Stator Pump
G Control Box
H Hopper
J Hopper Grate
K Motor Latch
L Pump Assembly Outlet
M Clean-Out Shaft
NWaterPump
PWaterPumpInlet
Q Water Pump System Bypass Outlet
R Water Flow Meter
S Wash-Down Hose
Ref. Description

Component Identification
63A4349B
Control Box
Control Box Control Panel
WLD
$$
&&
''
((
%%
))
7
9
=
<
8
:
Ref. Description
AA Power Out Connector
BB Main Power In Connector
CC Water Valve Connector
DD Water Pressure Connector
EE Remote Switch Connector
FF Water Pump Connector
WLD
0$,132:(5
32:(521 3803581 9)')$8/7
):'5(9
63(('
6(/(&725
:$7(535,0( :$7(536, :$7(53803
67$57
6723
21
2))



:
=<
8
9
7
Ref. Description
T Main Power Disconnect Switch
U Start/Stop Push Button
V Speed Selector Knob
W Forward/Reverse Pump Direction Switch
Y Water Prime Button
Z Water Pump Button

Component Identification
3A4349B 7
Water Pressure Over-ride Plug (OP)
The water solenoid valve requires 40 psi of water pressure to be energized. If the water pressure is not 40 psi or
greater, the solenoid valve will remain normally closed, blocking the flow of water. This operation can be overridden
by unplugging the water pressure connector (DD) and connecting the water pressure override plug (OP). This mimics
the signal that water pressure of 40 psi or greater is present, even when it is not.
WLD
23
''

Set Up
83A4349B
Set Up
NOTE: For letter references, see the Component
Identification section, starting on page 5.
1. Assemble the drive/mix shaft (D) into the hopper
and engage the flat end as shown below into the
slot of the rotor (RS).
A
2. Slowly swing the motor assembly toward its closed
position, stopping shortly before the motor shaft
adapter (MS) and drive/mix shaft (D) touch.
3. Make sure the motor shaft adapter (MS) and
drive/mix shaft (D) are aligned so the drive shaft flat
slides into the motor shaft adapter slot. If they do not
align, rotate them into position.
4. Swing the motor completely shut and lock it in place
with the motor latch (K).
WLD
'
56
WLD
06
'
/
WLD
'
06
WLD
.

Set Up
3A4349B 9
5. Secure the hopper grate (J) onto the top of the hop-
per (H).
6. Connect the motor cable (C) to the power out con-
nector (AA).
7. Connect power cable (B) to the main power in con-
nector (BB).
8. Connect the power cable (B) to an appropriate
power source.
Electrical Connections
Power Cable Color Code
Grounding
The system is grounded through the power cord.
To help prevent injury from moving parts, do not
operate with the grate (J) removed.
WLD
C
AA
Power Cable MTA727
(for systems 25M060, 25M061):
Line 1 Black
Line 2 White
Ground Green
Power Cable MTA728 (for systems 25M062):
Line 1 Black
Line 2 White
Line 3 Red
Ground Green
Power Cable MTA817 (for systems 25M063):
Line 1 Black
Line 2 White
Line 3 Red
Neutral Orange
Ground Green
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.

Operation
10 3A4349B
Operation
NOTE: For letter references, see the Component
Identification section, starting on page 5.
Priming with Water
1. Attach a water feed hose to the water pump inlet
(P).
NOTE: The water pump inlet is 3/4 in. female gar-
den hose fitting.
NOTE: The water feed must be able to supply water
pressure of 40 psi or greater, or else the pump will
not operate in the forward direction. A pressure
switch that controls the pump forward direction
operation activates at 40 psi and allows forward
operation. If water pressure is below 40 psi and the
pump must be operated in the forward direction, the
pressure switch can be bypassed by connecting the
water pressure bypass plug.
2. Attach the hose to the water pump system bypass
outlet (Q) and attach the spray applicator to the
hose outlet.
3. Place the applicator into a waste container.
4. Turn the main power disconnect switch (T) to ON.
5. Open the ball valve directly before the water pump
system bypass outlet (Q).
6. Press the water pump button (Z) to turn on the water
pump.
7. Run water until water flows from the end of the
applicator.
8. Press the water pump button (Z) to stop the water
pump and close the ball valve directly before the
water pump system bypass outlet (Q).
9. Run clean-out ball(s) to coat the inside of the hoses:
a. Remove the applicator from the end of the
hose.
NOTICE
To prevent material curing in the system, never load
material into a dry system. Loading material into a dry
system will cause the material to stick to components
and cure, causing damage and requiring replacement
of those parts.
WLD
P
Q
NOTICE
Do not allow the water pump to operate with no flow
for more than five minutes. The water pump can
become overheated and become damaged.
WLD
0$,132:(5
32:(521 3803581 9)')$8/7
):'5(9
63(('
6(/(&725
:$7(535,0( :$7(536, :$7(53803
67$57
6723
21
2))



:
=<
8
9
7

Operation
3A4349B 11
b. Remove the hose inlet from the water pump
system bypass outlet (Q) and place a hose
clean-out ball within the hose inlet. The ball
must be wetted down before inserting. If using a
1 in. whip hose, begin with the smallest
clean-out ball.
c. Reattach the hose to the water pump system
bypass outlet (Q), open the ball valve, and
press the water pump button (Z) to resume
flushing the hose.
d. The clean-out ball will be pushed out of the
hose after several minutes. Once the ball is
pushed through the hose, press the water pump
button (Z).
e. If using a 1 in. whip hose, remove the hose and
transition fitting and repeat the process using
the large clean-out ball on the remaining hoses.
Once the ball is pushed out, stop the water
pump and reattach the transition fitting and whip
hose.
f. Upon completion, close the ball valve, remove
the hose inlet from the water pump system
bypass outlet (Q), and attach the hose inlet to
the pump outlet (L).
10. Remove the Geka fitting cap (GF) from the lower
port.
11. Press the water pump button (Z), then hold the
water prime button (Y) for several seconds. Once
water flows from the lower port, release the water
prime button (Y).
NOTE: If water does not fill the mixing chamber, see
Startup After Extended Storage, page 18, or con-
tact Graco Technical Support.
12. Add dish soap or a slicking agent to the water
through the lower port and replace the Geka fitting
cap (GF).
NOTE: When priming with water, add dish soap or a
slicking agent to help lubricate the pump. Priming
with water only may cause excessive pump friction,
producing a high pitch noise and premature pump
wear.
13. Turn the speed selector knob (V) to speed 1 and
press the START button (U). If the pump does not
turn within five seconds, press the STOP button (U)
and follow the next step. If the pump turns, skip step
14 and proceed onto step 15.
NOTE: Do not run the rotor/stator pump with water
for more than five minutes at a time or premature
pump wear may occur.
14. If the pump did not turn within five seconds, perform
the steps below:
a. Press the START button (U) and quickly turn
the pump direction switch (W) between forward
and reverse.
NOTE: The pump direction switch (W) is nor-
mally in the FWD position. The switch must be
held in the REV position to reverse the pump
direction. The switch will return to the FWD
position when it is released.
NOTE: If the pump has not been broken free
after five seconds, press the STOP button (U)
or the motor control could encounter an over-
load error. After multiple attempts to free the
pump, allow the motor to cool for one minute.
b. If the rotor does not turn freely in the pump
assembly. See Troubleshooting, page 20.
15. Remove the hose inlet from the pump outlet (L) and
walk the water out of the hose.
a. Starting at the pump, raise the hose bundle
above your head and slowly move towards the
applicator end. As you move towards the appli-
cator end, the remaining water will drain from
the hoses.
16. Perform Pump Pressure Setting procedure, page
12.
17. Reattach the hose to the pump outlet (L). The sys-
tem is ready to prime with material.
Q
WLD
*)

Operation
12 3A4349B
Pump Pressure Setting
1. Attach the pressure test hose (A) to the pump outlet
(L) with the pressure test hose ball valve turned to
OPEN.
2. Place the end of the hose in a waste container.
3. Press the water pump button (Z) and START button
(U). Water should flow from the outlet of the pres-
sure test hose.
4. Set the water flow meter (R) to the approximate
level needed for spraying material.
5. Use the speed selector knob (V) to change the
pump speed to level 2.
6. Slowly close the pressure test hose ball valve.
7. Observe the pressure setting on the pressure gauge
and adjust the stator to achieve the desired pres-
sure. To adjust the stator and increase pump pres-
sure, evenly tighten the stator bolts until the desired
pressure is achieved.
NOTE: Over-tightening the stator can wear out the
stator prematurely. Under-tightening the stator will
cause the pump to under perform and have reduced
output.
8. After adjusting the stator bolts to set the pressure,
press the STOP button (U) and water pump (Z) but-
ton.
9. Slowly open the ball valve on the pressure test hose
(A) to relieve any remaining pressure.
10. Remove the pressure test hose (A) from the pump
outlet (L).
WLD
L
A
WLD
0$,132:(5
32:(521 3803581 9)')$8/7
):'5(9
63(('
6(/(&725
:$7(535,0( :$7(536, :$7(53803
67$57
6723
21
2))



:
=<
8
9
7
WLD

Operation
3A4349B 13
Prime with Material
1. Prime the system with water. See Prime with
Water, page 10.
2. Remove the applicator.
3. Remove the hose inlet from the pump outlet (L) and
place a waste tray below the pump outlet.
4. Add dry material:
Set a bag of material on the center of the hopper
grate (G) so the teeth are in the middle of the bag.
Twist the bag 15 degrees in both directions to rip
open, and lift both ends of the bag so the dry mate-
rial falls into the hopper. Dispose of the bag.
NOTE: Keep the hopper filled with dry material
when priming with material and spraying.
5. Press the water pump button (Z) and START button
(U). Material should start to flow from the pump out-
let (L).
6. Adjust the water flow meter (R) until the desired
material consistency is achieved.
7. Press the STOP button (U) and water pump button
(Z).
8. Reattach the hose to the pump outlet (L).
9. Press the water pump button (Z) and START button
(U). Pump until any remaining water is purged out of
the hose and a steady stream of material flows from
the hose outlet.
10. To stop dispensing, press the STOP button (U).
11. Install the applicator.
NOTE: For materials prone to packing out, before
installing the applicator, prime the larger ID hose,
then install and prime the transition fitting and whip
hose.
12. Press the START button (U) to start dispensing and
pump until material exits the applicator.
13. Press the water pump button (Z) and STOP button
(U) to stop dispensing.
14. Install the air line and a tip onto the applicator (see
the applicator manual). The system is now primed
and ready to spray.
Adding material to the hopper generates clouds of
dust, and exposes the user to the sharp teeth on
the hopper grate. Always wear protective equip-
ment when adding material to the hopper.
WLD
0$,132:(5
32:(521 3803581 9)')$8/7
):'5(9
63(('
6(/(&725
:$7(535,0( :$7(536, :$7(53803
67$57
6723
21
2))



:
=<
8
9
7

Operation
14 3A4349B
Spray
Prevent Pack-Out
To avoid “packing out” the pump or hose:
• Use the lowest pressure and largest nozzle size that
provides an acceptable spray pattern. This will also
result in wear parts lasting longer.
• Do not use any more material hose than is neces-
sary (minimum 25 ft, or 7.6 m).
Before Starting or Stopping Material Flow
Always have the atomizing air turned on at the
applicator before and after spraying fluid (see
applicator manual).
Spraying
1. Prime with Water, page 10.
2. Perform the Pump Pressure Setting procedure,
page 12.
3. Prime with Material, page 13.
4. Turn on atomizing air and adjust the air output to the
required level (see applicator manual).
5. Turn the main power disconnect switch (T) to ON
and press the water pump button (Z) and START
button (U) to spray material.
6. If the system is approaching its cure time, or if the
system will be idle for enough time for material to
begin curing in the system, Flush the system (see
page 16).
To help prevent injury from moving parts, do not
operate with the grate (J) removed.
NOTICE
Failure to flush prior to material curing in the system
will result in damage to the system and may require
replacement of all system parts in contact with
material.
WLD
0$,132:(5
32:(521 3803581 9)')$8/7
):'5(9
63(('
6(/(&725
:$7(535,0( :$7(536, :$7(53803
67$57
6723
21
2))



:
=<
8
9
7

Operation
3A4349B 15
Pressure Relief Procedure
1. Push the STOP button (U).
2. Remove the applicator tip and tip retainer, and hold
the applicator firmly against a pail.
3. Turn the speed control knob (V) to speed 1.
4. Hold the pump direction switch (W) in the REV
position and push the START button (U).
5. Allow the pump to run in reverse for several sec-
onds while holding the pump direction switch (W) in
the REV position.
NOTE: If the pump is stalled, do not run the pump
for more than five seconds at a time or the motor
control could encounter an overload error. After
multiple attempts to free the pump, allow the motor
to cool for one minute.
6. Push the STOP button (U) after five seconds and
release the pump direction switch (W). The switch
will return to its normal FWD position.
7. Turn the main power disconnect switch (T) to OFF.
8. Allow time for material to drain to relieve any
remaining pressure.
9. If you suspect the applicator or hose is still clogged
or that pressure has not been fully relieved after fol-
lowing the previous step.
a. Starting at the applicator, VERY SLOWLY open
the coupling while maintaining control of both
the applicator and hose.
b. Clear the hose or tip obstruction. If there is still
pressure trapped down the line, work your way
back to the pump by individually opening each
coupling between each hose connection. Main-
tain control of each hose and VERY SLOWLY
open each coupling until pressure has been
fully relieved.
Follow the Pressure Relief Procedure
whenever you see this symbol.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as splashing fluid and moving
parts, follow the Pressure Relief Procedure when you
stop dispensing and before cleaning, checking, or ser-
vicing the equipment.

Operation
16 3A4349B
Flush
1. With the pump stopped, turn the speed control knob
(V) to speed level one.
2. Remove the applicator tip and retainer.
3. Place the applicator outlet in a waste container.
4. Flush material from the hopper and the mixing
chamber.
a. Press the water pump button (Z) and START
button (U) to begin flushing out any remaining
material until the hopper is empty.
b. Once the hopper is empty of all material, press
the STOP button (U) to stop the pump.
c. Rinse the hopper (H) with the attached water
wash-down hose (S).
d. Press the START button (U) and run the pump
until no water is left inside the hopper.
5. If there is still material left in the mixing chamber
after flushing with water, the use clean-out shaft
(M).
a. Turn the main power disconnect switch (T) to
OFF.
b. Undo the motor latch (K) and swing the motor
assembly (E) open.
c. Remove the drive/mix shaft (D) and replace with
the clean-out shaft (M).
NOTE: Only use the clean-out shaft (M) if mate-
rial cannot be cleaned using normal flushing
means. Excessive use of the clean-out shaft
can cause premature wear to the system.
d. Slowly swing the motor assembly toward its
closed position, stopping shortly before the
motor shaft adapter (MS) and clean-out shaft
(M) touch.
e. Make sure the motor shaft adapter (MS) and
clean-out shaft (M) are aligned so the clean-out
shaft flat slides into the motor shaft adapter slot.
If they do not align, rotate them into position.
f. Swing the motor completely shut and lock it in
place with motor latch (K).
g. Turn the main power disconnect switch (T) to
ON and press the water pump button (Z).
h. Fill the hopper (H) with water and a slicking
agent or dish soap.
i. Press the START button (U) and run the pump
until no water is left in the hopper. Press the
STOP button (U) and water pump button (Z) to
stop the pump.
NOTICE
Failure to flush prior to material curing in the system
will result in damage to the system and may require
replacement of all system parts in contact with
material.
WLD
0$,132:(5
32:(521 3803581 9)')$8/7
):'5(9
63(('
6(/(&725
:$7(535,0( :$7(536, :$7(53803
67$57
6723
21
2))



:
=<
8
9
7
WLD
D
M

Operation
3A4349B 17
j. Make sure the mixing chamber is clean. If not,
repeat step 5h and 5i until clean.
k. Repeat steps 5a through 5f, but replace the
clean-out shaft (M) with the drive/mix shaft (D).
6. Once the hopper and mixing chamber are clean,
remove the hose inlet from the pump outlet (L) and
attach the hose to the water pump system bypass
outlet (Q).
NOTE: The rotor/stator pump should be used as lit-
tle as possible when flushing. Once the system is
clean, it is important to use the direct output from
the water pump during the remaining flushing proce-
dure to increase the life of the rotor and stator.
7. Open the water pump outlet ball valve and press the
water pump button (Z). Run until heavy sediment
has been flushed and clean water begins to exit the
applicator outlet.
8. Press the water pump button (Z) to stop dispensing
and close the ball valve.
9. Remove the applicator and clean/flush separately.
a. Make sure all parts are free of residual material.
b. Turn on air to make sure air lines are free of
obstructions.
10. Remove the remaining material in the hoses with a
a hose clean-out ball:
a. Place the hose outlet into a waste container.
b. Remove the hose inlet from the water pump
outlet and place a hose clean-out ball within the
hose inlet. The ball must be wetted down before
inserting. If using a 1 in. (25 mm) whip hose,
begin with the smallest clean-out ball.
c. Reattach the hose to the water pump system
bypass outlet (Q), open the ball valve, and
press the water pump button (Z) to resume
flushing the hose.
d. The hose clean-out ball will be pushed out of
the hose after several minutes. Once the ball is
pushed through the hose, press the water pump
button (Z). Repeat until all sediment is removed
from the hose.
e. If using a 1 in. (25 mm) whip hose, remove the
hose and transition fitting and repeat the pro-
cess using the large clean-out ball on the
remaining hoses. Once the ball is pushed out,
stop the water pump and reattach the transition
fitting and whip hose.
11. Turn the main power disconnect switch (T) to OFF.
12. Dispose of all waste material in accordance with
local rules and regulations. See manufacturer SDSs
for additional information.
Shutdown
1. To shutdown, flush the system (Flush, page 12).
2. Disconnect from the power supply.
3. Drain water from the water pump system.
WLD
NOTICE
In cold environments, water left in the pump system
could freeze and damage the equipment. When work-
ing in cold environments, drain all water from the
pump system to avoid damage.

Operation
18 3A4349B
Winterizing and Extended
Storage
1. Connect the power cable to the appropriate power
source and turn the main power disconnect switch
(T) to ON.
2. If connected to the water pump inlet, disconnect the
water feed hose.
3. Disconnect the water assembly hose (WH) from the
water assembly control inlet (WC). Loosen the drain
cock (DC) behind the water flow meter, fully open
the water flow meter valve (R), and then open the
spray gun latch (S) on the water wash-down hose.
4. Press and hold the water prime button (Y) until
water has stopped draining from all openings, then
release the button.
5. Press the water pump button (Z) to turn the water
pump on and let it run for 15 seconds to expel any
excess water. Press the button again to stop the
water pump.
6. Turn the main power disconnect switch (T) to OFF
and disconnect from the power supply.
7. Leave all components open and detached until the
next use.
8. Make sure the motor has been fully greased and the
mixing pump has been thoroughly cleaned and no
material remains.
Startup After Extended Storage
Reassemble all disconnected hoses and close all water
drain openings before startup.
If the pump will not startup after an extended period of
storage, perform the following steps:
1. Loosen the three bolts on the end cap by approxi-
mately two turns.
2. Insert a flat screwdriver blade into the provided slots
between the end cap and the pump head.
3. Gently pry on both sides until the cover lifts off the
pump head.
4. Restart the water pump and observe that it starts up
and operates correctly. While the pump is running,
tighten the three bolts.
5. Press the water pump button (Z) to turn off the water
pump and press and hold the water prime button
(Y).
6. Slowly open the flow meter valve until water can be
seen passing through the flow meter.
7. Release the water prime button (Y) and make sure
the water has stopped. The mixing pump is now
ready for use.
WLD
:+ 6
5
'&
:&
ti29595a
X2

Operation
3A4349B 19
Routine Maintenance
The following maintenance should be
performed daily:
1. Flush the system (see Flush, page 12).
2. Perform the Pressure Relief Procedure, page 8.
3. Clean the hopper with a scrub pad. It is recom-
mended that you clean the outside of the sprayer
with a cloth and water.
4. Check the pump, seals, hoses, couplings, and
cables for wear and damage. Replace if necessary.
5. Grease seals daily via the grease fitting (GF)
located on the motor flange. Use water resistant,
corrosion inhibited grease.
NOTICE
Failure to clean properly after use will damage seals
and moving parts due to wear from material build-up.
To avoid damage, properly clean the unit after each
use.
WLD
*)
*)

Troubleshooting
20 3A4349B
Troubleshooting
Problem Cause Solution
The rotor/stator pump oper-
ates, but output is low
Pump pressure is too low, stator
is too loose.
Tighten stator to achieve suitable pumping
pressure.
Pump pressure is too high, stator
is too tight.
Loosen stator to achieve suitable pumping
pressure.
Stator is worn or damaged. Tighten stator. If low output continues,
replace stator.
Rotor is worn or damaged. Tighten stator. If low output continues,
replace stator.
Material hose is clogged. Clean or replace the material hose.
Applicator or tip is dirty or
clogged.
Clean or replace the applicator or tip.
Large pressure drop in material
hose.
Reduce hose length and/or increase
diameter.
Pump does not operate Stator sleeve is too tight. Evenly loosen the stator bolts to reduce pres-
sure. If the pump still does not operate when
bolts are loose, engage the jacking screw (JS)
to further open the stator sleeve. This should
reduce pressure enough to allow the pump to
run. Once running, re-tighten the stator bolts
to achieve appropriate pump pressure.
VFD overload fault. Turn power disconnect switch to OFF and
wait one minute for VFD to reset. See “VFD
overload fault,” below, for possible causes.
Material hose or applicator is
obstructed.
Clean or replace the hose or applicator.
Dried material in pump assem-
bly.
Clean or replace the pump assembly.
WLD
-6