ROYAL Cyclone 1 Extruder Operators’ Instruction Manual

P/N 161385 Rev 9/14

WARNING! THIS MACHINE IS DESIGNED FOR USE ON FLAT, LEVEL

ROOFS ONLY.

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.

Read and understand the

instructions in this Manual

before using this machine!

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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 Work-er 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 possi-ble. This means taking only the tools you need to the roof edge, removing all trip haz-ards 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.

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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 equip-

ment 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 recommenda-

tions of material manufacturer. Consult your local OSHA office regarding respi-

rator 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 construc-

tion. Servicing electrical components should only be done by trained personnel and

only after disconnecting power to the equipment.

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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.

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.

TO PREVENT MATERIAL CROSSOVERS IN THE GUN AND HOSES: The Static Mixing Tips are disposable and should be removed from the Gun assembly dur-ing 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.

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3. SHUTTING DOWN OR DURING EXTENDED BREAKS:

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 dis-

card 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.

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.

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.

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 absorb-ing moisture from air.

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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

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9

Ro

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Trou

ble

sho

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uid

e

161514

Symp

tom

Ch

eck

So

luti

on

Mo

tor clicks o

n an

d o

ff freq

uen

tly.

1. Le

aking at th

read

ed

join

ts on

Part 2

side

.

1. Tigh

ten

join

ts wh

ere need

ed.

2. C

he

ck Valve

no

t seati

ng p

rop

erly.

2

. Re

mo

ve and

clean o

r replace C

heck V

alve.

Mo

tor w

ill no

t start wh

en valves are

o

pen

ed.

1

. Circu

it Bre

aker ben

eath

ele

ctrical bo

x or

Po

we

r Switch

no

t switch

ed to

"ON

"

1. Flip

Circu

it Breaker an

d/o

r Po

we

r Switch

to

"ON

"

2. C

logge

d M

anifo

ld o

r Mixin

g Tip.

2

. Clean

Man

ifold

or ch

ange M

ixing Tip

3. C

he

ck Mo

tor w

iring fo

r loo

se co

nn

ecti

on

s. TO

BE D

ON

E BY

A Q

UA

LIFIED ELEC

TRIC

IAN

!

3. Fix lo

ose co

nn

ectio

n(s). If co

nn

ectio

ns are

go

od

, Mo

tor m

ay be b

urn

ed o

ut. R

eplace.

Mo

tor co

nti

nu

es to ru

n w

hen

valves are

closed

.

1. Fau

lty Pre

ssure

Switch

1. R

ep

lace Switch

. Ord

er Parts K

it 40825

4

Leaky Q

uick C

on

nect Fitti

ngs w

here In

let H

ose co

nn

ects to b

ott

om

of B

ladd

er.

1. W

orn

or b

roken

Qu

ick Co

nn

ect Fitti

ng.

1

. Re

place Q

uick C

on

nect Fitti

ng

2. M

isalignm

en

t of B

ag in Tray.

2

. Mo

ve Bag to

achieve b

etter align

me

nt an

d

rem

ove an

y side lo

ad o

n Fitti

ng.

3. H

ose

Clam

p n

ot ti

ght.

3

. Tighte

n C

lamp

. Do

no

t crush

Ho

se.

4. En

d o

f Inle

t Ho

se w

orn

, cracked o

r britt

le.

4

. Re

place In

let Ho

se

Un

equ

al amo

un

ts of A

dh

esive are b

eing

used

1. Le

aky Qu

ick Co

nn

ect Fitti

ng

1

. Re

place Q

uick C

on

nect Fitti

ng

2. In

let h

ose

collap

sed

2. R

ep

lace inlet h

ose

3. C

he

ck adh

esive

flo

w at e

nd

of m

anifo

ld. R

e-

mo

ve m

ixing ti

p / P

lace e

qu

al-sized

con

taine

rs (co

ffe

e cu

p, jar, b

ott

le..e

tc.) un

de

r each

stream

o

f the m

anifo

ld fo

r 10

- 15

seco

nd

s. Bo

th co

n-

taine

rs sho

uld

have

eq

ual vo

lum

es; if n

ot,

che

ck for le

aks and

blo

ckages. C

on

sult w

ith

man

ufactu

rer if p

rob

lem

con

tin

ue

s.

3. C

lear blo

ckage / replace clo

gged, w

arn o

r b

roken

com

po

nen

ts

10

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This page intentionally left blank to allow equipment owner to remove back page of manual and turn it in to register for warranty.

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