Repair
™
309518P
ENG
Xtreme Mix
Plural Component Proportioner
For spraying two-component protective coatings.
Not approved for use in explosive atmospheres.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions
See page 3 for model information, including maxi-
mum working pressure and approvals.
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Xtreme Mix Models
Xtreme Mix Models
WARNING
Do not install equipment approved only for non-haz-
ardous location in a hazardous area. Substitution of
Approved for Non-hazardous Location
Xtreme
Mix
Maximum Working
Pressure
Pump
Pump
Part No.
Series
Part No.
Description
psi (MPa, bar)
Approvals
233863
233864
233865
233866
233867
233868
233869
233870
*248842
A
A
A
A
A
A
A
A
A
249274
249275
249276
249277
249278
249279
249280
249281
249276
45:1 King
56:1 King
68:1 King
4500 (31, 310)
5600 (38.6, 386)
6800 (46.9, 469)
7250 (50, 500)
4500 (31, 310)
5600 (38.6, 386)
6800 (46.9, 469)
7250 (50, 500)
5000 (34.5, 345)
80:1 King
45:1 Quiet King
56:1 Quiet King
68:1 Quiet King
80:1 Quiet King
68:1 King
Remote Mix
*Model 248842 is designed for remote feed pumps and a remote mix manifold. It does not include hoppers, mix
manifold, hose, or spray gun. Refer to manual 310794 for application layout.
Model 248842 is limited to 5000 psi (34.5 MPa, 345 bar) for use in “quick set” packages where heated hoses,
whip hoses, and spray accessories are limited to 5000 psi (34.5 MPa, 345 bar). If all your downstream compo-
nents are rated for 7000 psi (48 MPa, 483 bar), you can replace the standard relief valve with relief valve
113498.
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Manual Conventions
Manual Conventions
Note
WARNING
Additional helpful information.
Hazard Symbol
Components A and B
WARNING: a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
IMPORTANT!
Warnings in the instructions usually include a symbol
indicating the hazard. Read the general Warnings
section for additional safety information.
Material suppliers can vary in how they refer to plural
component materials.
Be aware that in this manual:
CAUTION
Component A refers to resin or major volume.
Component B refers to catalyst (curing agent) or minor
volume.
CAUTION: a potentially hazardous situation which, if
not avoided, may result in property damage or
destruction of equipment.
Related Manuals
Component Manuals
This manual available in following languages:
Manual
Description
Manual
Language
Manual
Language
309535
311762
309347
Xtreme Mix Operation
Xtreme Displacement Pump
King Air Motor
309518
309564
309565
English
French
309609
309610
309611
Italian
Finnish
Swedish
Brazilian
Portuguese
or 309348 King Quiet Air Motor
309566
309567
309608
310752
310777
Spanish
German
Greek
309612
309613
309614
310753
Chinese
Korean
312145
309524
309525
308981
309615
309568
310797
310794
310863
309827
XTR Spray Gun
VISCON HP Heater
Heated Hose Kit
Japanese
Norwegian
Dutch
Husky 716 Diaphragm Pump
Heater Bracket Kit
Danish
Remote Manifold Kit
Remote Mix Manifold
Remote Mix Proportioning Systems
Feed and Flush Kits
Air Supply Kits
4
309518P
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Warnings
Warnings
The following general warnings are related to the safe setup, use, grounding, maintenance, and repair of this equip-
ment. Additional more specific warnings may be found throughout the text of this manual where applicable.
Warning
FIRE AND EXPLOSION HAZARD
Flammable 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 equipment and conductive objects in 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 fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
•
Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
•
•
Connect only to grounded power source.
All electrical wiring must be done by a qualified electrician and comply with all local codes and regu-
lations.
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 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.
Do not spray without tip guard and trigger guard installed.
Engage trigger lock when not spraying.
Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
MOVING PARTS HAZARD
Moving parts can pinch 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 in this manual. Disconnect power or air supply.
309518P
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Warning
Warning
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•
Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-
ponent. 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.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not alter or modify equipment.
•
•
•
•
•
•
•
For professional use only.
Use equipment only for its intended purpose. Call your Graco distributor for information.
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
Do not kink or overbend hoses or use hoses to pull equipment.
Comply with all applicable safety regulations.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns,
do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
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 swal-
lowed.
•
•
Read MSDS’s 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
You 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, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
•
•
•
•
Protective eyewear
Clothing and respirator as recommended by the fluid and solvent manufacturer
Gloves
Hearing protection
RECOIL HAZARD
Gun may recoil when triggered and cause you to fall and be seriously injured if you are not standing
securely.
6
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Pressure Relief Procedure
Pressure Relief Procedure
6. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger gun to relieve pressure.
WARNING
spraying and before cleaning, checking, servicing, or
transporting equipment. Read warnings, page 5.
TI5046A
1. Engage trigger lock.
7. Engage trigger lock.
2. Press Stop
.
8. Place waste container under sampling valves, then
open valves A and B slowly to relieve pressure
between pump and metering valve.
PL
U
RAL COMPONEN
T
PROPORTI ONER
3. Close main air shutoff valve on air supply line and on
unit. Turn off air regulator.
Open
Open
Close
Close
4. Close fluid sampling and shutoff valves A and B.
A
B
M
Close
Close
9. Close sampling valves A and B.
Close
Close
PSI
Bar
MP
A
B
Close
Close
5. Disengage trigger lock.
A
B
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Proper Lifting of Unit
Proper Lifting of Unit
WARNING
Follow instructions below to avoid dropping or swing-
ing unit or being struck by the cart handle, which can
cause serious injury or damage to equipment.
Either remove the cart handle or secure it to the cart
before lifting the unit. Connect a bridle swing, hooking
an end to each of the Xtreme Mix air motor rings. Hook
Xtreme Mix unit; make sure it balances evenly.
FIG. 1
Grounding
WARNING
Read warnings, page 5.
If the Xtreme Mix ground wire clamp (G) is disconnected
during repair, be sure to reconnect it to a true earth
ground before starting operation.
G
FIG. 2
8
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Shutdown
Shutdown
Maintenance
Follow this procedure before prolonged shutdown or
servicing equipment.
Metering Valve
•
Fill metering valves A and B packing nuts (627) with
throat seal liquid (TSL) and tighten 1/4 turn after nut
contacts packings; about 145-155 in/lbs (16-18
N•m). Check packing nut tightness after first hour of
operation, again after 24 hours, then check as
needed (when TSL discolors or seeps over packing
nut). Also check tightness whenever unit is trans-
ported.
If your system includes heaters and heated hose,
make sure they are turned off and cool before
flushing.
trigger lock, turn off air regulator, and close main air
shutoff valve. Remove spray tip.
•
Recommend that you replace metering valve pack-
ings every other time that pump packings are
replaced.
627
PSI
Bar
MP
O
TI5193
2. Follow Full System Flushing procedure in the
Xtreme Mix Operation manual.
Engage trigger lock.
4. Before prolonged shutdown: cap fluid outlets to
keep solvent in the lines. Fill pump A and B packing
nuts with throat seal liquid (TSL); follow instructions
in pump manual.
Pump
See pump manual.
Turbine Alternator
Replace bearings every 2000 hours. See page 20.
Air Filters
Check daily. Drain and clean as necessary. See page
16.
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Pump Test
Pump Test
Follow this procedure the first time system is operated
(after flushing and priming) and whenever you need to
check whether pumps are on ratio.
c. Press Start
. Pump A light comes on.
d. Slowly open and adjust sampling valve A to
achieve desired flow. The pump stops automati-
cally when dispense is complete. Pump A light
turns off, Pump B light comes on.
The following table shows the volume dispensed during
the pump test, based on your pump ratio. Dispense into
a container with adequate graduations.
I
r
Ia
Pump
Volume Dispensed
c.
45:1
56:1
68:1
80:1
750 cc
660 cc
540 cc
435 cc
Open
d.
1. Turn knob to pump test
. Turn off air regulator.
Open main air shutoff valve. Adjust air pressure to
50 psi (0.35 MPa, 3.5 bar).
A
A
B
0
3. Close sampling valve A.
B
A
I
r
PIa
Close
A
2. Dispense fluid A:
a. Close fluid shutoff valves and sampling valves A
and B.
4. Dispense fluid B as follows:
b. Place a clean 1 quart (1000 cc) container under
sampling valve A.
a. Place a clean 1 quart (1000 cc) container under
sampling valve B.
b. Slowly open and adjust sampling valve B to
achieve desired flow. The pump stops automati-
cally when dispense is complete. Pump B light
turns off.
Close
Close
a.
b.
a.
A
Open
b.
B
a.
10
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Pump Test
5. Close sampling valve B.
Close
B
6. Compare fluid amounts in the containers; they
should be equal. Repeat test if fluids are not equal.
12.
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Troubleshooting
Troubleshooting
WARNING
Read warnings, page 5.
Problem
Cause
Solution
Display not lit.
Air valve not turned on.
Turn on main air valve to system.
No electric power.
Air supply pressure too low.
Increase pressure to 50 psi (0.35 MPa,
3.5 bar) or greater.
Air supply filters plugged.
Clean filter bowls; replace filter elements.
Turbine air regulator set too low.
Turbine alternator failure.
Adjust to proper setting.
Power supply not connected to main
board.
Check power connections to main board.
Main board not connected to display
board.
Check electrical connections between
display and main board. See Electrical
Display board failure.
Replace display board. Page 18.
Set knob to desired setting.
Pumps do not run.
Knob set to cycle counter
Air pressure to pumps too low
Increase pressure to 50 psi (0.35 MPa,
3.5 bar) or greater.
Air pilot lines are obstructed
Solenoid valve stuck.
Check pilot lines for kinks or pinches.
Actuate solenoid manually, if it does not
operate, replace solenoid. Page 21.
Air pilot valve(s) to motor stuck.
Metering valve(s) not opening.
Air pressure to pumps too low
Pump test volume is not correct.
Increase pressure to 50 psi (0.35 MPa,
3.5 bar) or greater.
Sensors not functioning properly.
Check position of sensors. See page 27.
Check board calibration and recalibrate if
Replace sensors. Page 27.
Pump cavitating excessively.
Check for air in lines caused by loose fit-
ting or use of agitator.
Material too viscous. Use heater.
12
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Troubleshooting
Problem
Cause
Solution
Paint does not cure consistently.
Ratio not set correctly.
Check that correct ratio is set and set by
volume. See Xtreme Mix Operation man-
ual.
Material not mixing correctly.
Pump not operating correctly.
Make sure mixer is clean; flush as
needed. See Xtreme Mix Operation man-
ual.
Observe whether pumps are loading and
checking correctly, if not, clean and repair
pump. See pump manual.
Poor spray pattern.
Fluid pressure too low.
Spray tip dirty or worn.
Increase pump pressure.
Relieve pressure. Clean or replace tip.
Follow gun manual instructions.
Fluid A or B filters plugged.
Clean filters. See pump manual.
Mixer or hoses partially plugged or too
restrictive.
Inspect parts for cured material. Clean or
replace, or use larger hoses and mixer.
System runs erratically.
Air filter(s) clogged. Replace elements.
Air supply hoses undersized.
Replace hoses with appropriate size.
Use larger air compressor.
Air compressor undersized.
Air supply pressure tank undersized.
Turbine air regulator set too high.
Use larger pressure tank.
Air supply relief valve opens.
Lower setting to 23-25 psi (172-241 kPa,
1.7-2.4 bar).
Turbine alternator makes high-pitched
whining noise.
Turbine bearings worn. (Setting turbine
air regulator too high, wears bearings.)
Display shows 88888 or unit reboots
unexpectedly.
Turbine is not supplying enough power to Increase turbine regulator setting to
board.
23-25 psi (172-241 kPa, 1.7-2.4 bar).
Check turbine and electrical control
exhaust air for restrictions.
Replace turbine bearings. Page 20.
Xtreme Mix does not start when start but- Faulty start switch or wire harness.
ton is pressed.
Check start switch and wiring harness
continuity; switch is normally open circuit.
Faulty stop switch or wiring harness.
Check stop switch and wiring harness
continuity; stop switch is normally closed
Bad I/O port on main board.
Replace board. Page 17.
Fluid valves leaking.
Loose or worn packings.
Tighten packing nut. If leak continues,
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Troubleshooting
Problem
Cause
Solution
Flow rate too low.
Inadequate air supply.
Use larger CFM compressor.
Increase pressure.
Air pressure to pumps too low.
Fluid A or B filters plugged.
Spray tip too small.
Clean filters. See pump manual.
Relieve pressure. Install larger tip. Follow
gun manual instructions.
Mixer or hoses partially plugged or too
restrictive.
Inspect parts for cured material. Clean or
replace, or use larger hoses and mixer.
Knob is set to Run pump A
independently.
or B
A
Turn knob to spray
rial.
if spraying mate-
Pump stops after 12 cycles.
B
Knob is set to Run pump A
independently.
or B
A
Turn knob to spray
rial.
if spraying mate-
Xtreme Mix makes chirping noise every
60 seconds.
B
Material too heavy to siphon or gravity
feed.
Change material feed/supply method.
14
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Alarms
Alarms
•
•
An alarm condition will shutdown the equip-
ment.
A chirping sound every 60 seconds indicates
the unit is set for recirculation mode.
*
Indicates error where audible alarm sounds once briefly.
** Indicates error where audible alarm sound pulses.
Code
Alarm
Active
Problem
Cause
Startup Errors
01
02
03
Sensor Error A*
Always No signal from pump A sensor.
Always No signal from pump B sensor.
Loose cable, failed sensor or cable.
Sensor Error B*
Controller Error*
Loose cable, failed sensor or cable.
Always Loss of communication between main
and display boards.
Loose cable, failed board. Page 17.
Operating Errors
Pump Runaway A**
Pump Runaway B**
04
05
Spray
Test
Batch
Pump running too fast.
This alarm is not active when
Empty fluid reservoir(s).
Clogged fluid filter.
pumps are run independently.
Hose rupture after mix manifold.
Sampling valve open too far.
Excessive cavitation.
Foot valve leak.
06
07
Pump Error A**
Pump Error B**
Spray
Test
Batch
Pump does not stall after top change
over.
Air in lines caused by loose fitting or
use of agitator.
Pump cavitating excessively.
Empty fluid reservoir(s).
08
Sensor Code Error
Always Software boot, sensor values reverted to Sensor value data corrupt; board
default.
needs replacement and /or recalibra-
09
10
Metering Error A**
Metering Error B**
Spray
Spray
A dose too great.
Empty B fluid reservoir.
B dose too great.
Empty A fluid reservoir.
11
12
Sensor Reading Low A*
Sensor Reading Low B*
Always Pump stroke travels beyond sensor
range at bottom change over.
Sensor or bracket loose. Page 27.
Sensor magnet dirty.
13
14
Sensor Reading High A*
Sensor Reading High B*
Always Pump stroke travels beyond sensor
range at top change over.
Sensor or bracket loose. Page 27.
Sensor magnet dirty.
Testing Error
Piston packing/ball A*
Piston packing/ball B*
Inlet Ball A*
15
16
17
18
19
20
Test
Test
Test
Pump does not completely stall in up
stroke.
Piston packing or ball check failure.
Pump does not completely stall in down- Foot valve ball check failure.
stroke.
Inlet Ball B*
Metering Valve A*
Metering Valve B*
Pump does not completely stall in both Throat packing or metering valve fail-
up and down strokes.
ure. Page 24.
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Repair
Repair
may exceed pot life time, before servicing fluid compo-
nents, and before transporting equipment to a service
area.
WARNING
Read warnings, page 5.
FIG. 4
Replacing Air Filter Element
4. Remove and replace element.
There are 2 air filters on the unit: the 5 micron air mani-
fold filter (518) and 40 micron pump air filter (8). Check
filters daily and replace element as needed.
5. Screw filter bowl on securely.
Pump Air Filter
WARNING
Removing the bowl of a pressurized air filter could
cause serious injury. Do not service air filter until air
line is depressurized.
Both Filters
1. Close main air shutoff valve on air supply line and
on unit. Depressurize air line.
FIG. 5
Air Manifold Filter
3. Unscrew plate.
43
42
FIG. 3
FIG. 6
5. Reassemble.
16
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Repair
User Interface
Removing Cover
C
D
1. Close main air shutoff valve on air supply line and
on unit.
3. Remove four nuts (32) and open user interface
FIG. 9
32
3. Install new chip (beveled corner down).
4. Reassemble.
Replacing Main Circuit Board
FIG. 7
CAUTION
To avoid damaging circuit board, wear a grounding
strap.
301
315
406
416
1. Remove User Interface cover. See above.
2. Disconnect all wire connectors from board (301).
3. Remove four screws (302) and replace board (301).
4
28.
FIG. 8
4. To completely remove cover (4), disconnect ground
wire (315), wires (416 and 406) from main board
28.
10
9
8
7
6
5
4
3
301
302
Software Upgrades
CAUTION
3
4
5
6
7
8
9
10
To avoid damaging circuit board, wear a grounding
strap.
1. Remove User Interface cover. See above.
-
+
2. Use a chip remover (D) to remove software chip (C).
FIG. 10
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Repair
Replacing Display Circuit Board
411
CAUTION
To avoid damaging circuit board, wear a grounding
strap.
410
2. Disconnect wires from display board (410). FIG. 11.
3. Remove two screws (411).
Ref.
416
4. Remove setscrew (B) from knob (405) and remove
knob assembly.
406
416
5. Remove and replace display board (410).
Back View
28.
B
1
405
1
Align knob to allow for turning to all 6 settings.
FIG. 11
18
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Repair
Recalibrate Circuit Board
Follow this procedure whenever the main circuit board,
software, or sensor is replaced, or when Alarm 8 occurs
1. Note calibration value on pump A sensor. Refer to
FIG. 23, page 27.
2. Open main air valve to start unit.
3. Turn knob to pump A
A
Stop button about 5 seconds. The default cali-
bration (number between 85000 - 95000) displays.
4. Use key (X) to change default to calibration value
noted previously.
5. Note calibration value on pump B sensor.
6. Turn knob to pump B
. Hold down Stop
B
button about 5 seconds. The default calibration dis-
plays.
7. Use key (X) to change default to calibration value
noted previously.
X
A
B
0
B
A
A or B
FIG. 12
If data download is used, set date and time after
calibrating, using Xtreme Mix software.
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Repair
Pneumatic Control
Alternator Repair
Turbine Alternator Repair Kit 223688 is available to
replace turbine bearings.
305
304
304d
306r
10
9
8
7
6
5
4
3
P
301
304
310
FIG. 14
3
4
5
6
7
8
9
10
310
A
-
+
304a
1
304d
FIG. 13
3. Disconnect two air lines (310) from alternator (304).
4. Remove top nut (305) and loosen bottom nut. Slide
alternator up and off bottom nut.
304e
5. Remove four screws (304d) to separate alternator
1
Torque to 20 in-lbs (2 N•m)
FIG. 15
6. Disconnect turbine (304e) from board (A). Follow
instructions in turbine kit manual 308034 to remove
and repair turbine.
7. Replace gasket (304a) if damaged. Place between
housings before securing with screws (304d).
28.
•
•
•
Lightly lubricate turbine o-ring before install-
ing turbine in housing.
Connect alternator red wire to + side and
black wire to – side of main circuit board.
Connect turbine to 3-pin connector on main
circuit board.
20
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Repair
3. Disconnect supply and exhaust air lines (310).
Replacing Solenoids
Follow this procedure to replace a single solenoid.
4. Disconnect solenoid wires 12 position Phoenix con-
5. Remove solenoid module (306) with regulator
(306e). FIG. 16.
2. Disconnect two solenoid wires (V) from main board.
FIG. 16.
6. Unscrew and replace regulator (306e).
3. Remove two screws (S).
4. Remove and replace solenoid (306b).
28.
From left to right, solenoid functions are as follows:
Make sure gaskets (306j, 306k) are in place when
reinstalling solenoid module.
•
•
•
•
Metering valve A
Metering valve B
Pump A
8. Set regulator to 24 psi (160 kPa, 1.6 bar).
Pump B
Replacing Alarm
5. Reassemble. Solenoid wires are polarized (red +,
2. Disconnect alarm wires from main board.
3. Unscrew alarm (313) and replace. FIG. 16.
Replacing Alternator Regulator
2. Remove two screws (309). FIG. 16.
28.
306
V
309
306k
S
310
306b
313
1
306e
306j
1
Set regulator pressure to 24 psi (160 kPa, 16 bar)
FIG. 16
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Repair
Sampling Valve
WARNING
Read warnings, page 5.
2. Unscrew sampling valve assembly (83) from meter-
ing valve (601).
3. Unscrew seat (83c).
4. Remove o-rings (83f), ball (83d), seat (83g), and
gasket (83h).
5. Replace parts as needed and reassemble.
601
83c
83h
83g
83d
83f
1
606 (side A)
611 (side B)
83b
83e
1
83a
2
607
84
85
1
2
Lubricate.
Apply anaerobic sealant. Torque to 130-140 in-lbs (15-16 N•m)
FIG. 18
309518P
23
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Repair
Servicing Metering Valve
Metering Valve/Manifold
Assembly
Follow this procedure to replace packings. Reference
numbers with * are included in repair kit 234098. Refer-
ence numbers with † are included in repair kit 234131.
WARNING
1. Remove metering valve.
2. Remove two locknuts (636). FIG. 20.
3. Remove packing nut (627).
Read warnings, page 5.
Removing Assembly
4. Remove inlet housing (628).
5. Unscrew needle (630*) from piston rod (625).
2. Disconnect top and bottom black air tubes.
3. Unscrew fluid tube.
6. Remove packings (637*, 638, 639*). Inspect needle
(630*) and replace if worn.
4. Remove nuts (26), screws (27, 48) and lockwashers
(25). FIG. 19.
If piston valve packings need replacement:
7. Unscrew cap (622).
5. Remove metering valve manifold (6).
8. Unscrew locknut (631).
Removing Metering Valve
9. Remove piston (623) and replace o-rings (632*†,
633*†, 634*†).
10. Replace piston rod o-ring (643*†) if damaged.
11. Reassemble.
2. Unscrew metering valve (601) from shutoff valve
(606 or 611).
3. If necessary, remove and repair or replace shutoff
valve (606 or 611). See manual 306861.
48*
27
25
25
601
48
25
606 (side A)
611 (side B)
6
Manifold
245833
48
25
607a
6
Manifold
248843
26
26
26
FIG. 19
24
309518P
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Repair
621
622
6
627
5
8
*† 637
8
639*†
*† 634
*† 632
*† 638
629
8
4
4
626
4
631
7
628
636
623
*† 633
† 635
3
630† 8
645*†
644†
9
10
645*†
9
624
9
646
647
*† 643
625
5
621
1. Apply pipe sealant to non-swiveling pipe threads.
2. Apply lubricant to threads, o-rings, and seals.
8
Clean needle (630) and packing cavity before reinstalling
packings (637*, 638, 639*). Lubricate packings and install with
lips facing up toward packing nut (627) in order shown.
3
Apply medium anaerobic adhesive. Thread to bottom.
Torque to 5-7 ft/lbs (7-9 N•m).
9
Whenever the seat housing (646) is removed, replace the o-rings
(645).
4
5
6
Torque to 30-40 ft/lbs (41-54 N•m).
10
Inspect reversible seat for damage. If one side is worn, reverse
seat.
Tighten packing nut 1/4 turn after nut bottoms out; 145-155 in/lbs
(16-18 N•m). Check packing nut tightness about once a month.
Keep packing nut filled with TSL.
7
Lubricate and press piston evenly into cylinder.
FIG. 20
309518P
25
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Repair
Servicing Fluid Manifold 245833
CAUTION
Follow this procedure to replace packings. Reference
numbers with * are included in repair kit 234100.
Do not assemble static mixer directly to fluid manifold.
Install static mixer after first 50 ft. (15 m) of hose to
ensure material is completely mixed. Spraying
unmixed material could necessitate rework of part
sprayed. See Setup in Xtreme Mix Operation manual.
2. Unscrew plug (661).
3. Remove and replace o-rings (662*, 663*, 665*),
seat (664*), ball (666*), and spring (667*).
Servicing Fluid Manifold 248843
There are no serviceable parts on manifold 248843.
4. Reassemble.
676
675
674
669
665
670
668
661
*662
*663
*665
*664
*665
*666
*667
Manifold 245833
1. Apply pipe sealant to non-swiveling pipe threads.
2. Apply lubricant to threads, o-rings, and seals.
FIG. 21
26
309518P
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Repair
Sensor
704†
CAUTION
†712
†714
703†
720†
To avoid damaging board, wear a grounding strap.
Reference numbers with * are included in repair kit
246345. Reference numbers with † are included in
repair kit 246344.
701†
710*
709*
1. Close main air shutoff valve on air supply line and
702*
4
†707
†706
VALVE
VALVE
A
B
3
0
SETUP KEY
DATA PORT
B
PSI
Bar
A
MPa
705*
719*
PSI
Bar
MP
713*
721*
Y
2
P
L
U
R
A
L
C
O
M
P
O
N
E
N
T
P
R
O
P
O
R
T
I
O
N
E
R
FIG. 22
2. Unscrew sensor cap (701†) from nut (712†). FIG.
23.
1
711*
†708
3. Disconnect cable (705*).
4. Unscrew fitting (713*), locknut (719*), and cover
(702*).
1
Torque to 60 in-lbs (7 N•m).
2
3
4
Plug connector into connector on board (703).
Calibration value location.
5. Disconnect sensor cable (Y) from board (703†).
6. Remove and replace parts as needed.
Before assembling cover (702*) to cap (701†), assemble cable
(705*) through fitting (713*) and cover (702*), and plug cable into
connector on board (703†) and to ground lug.
FIG. 23
Mount sensor as close to magnet as possible
without touching it.
Displacement Pump
2. Disconnect 90° swivel (30) from pump lower. Refer
WARNING
3. Remove pump lower and service as instructed in
pump manual 311762.
Read warnings, page 5.
309518P
27
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Electrical Schematic
Electrical Schematic
ꢀ
*ꢄ
ꢀ
ꢀ
ꢂ
ꢅ
ꢀꢈ6$#
#/-
2
",
ꢂ
ꢅ
Jumper (15V)
Main Circuit
Board
245705
ꢀ
*ꢈ
Solenoids
ꢀ
ꢀ
ꢂ
ꢅ
ꢂ
ꢅ
ꢇ
ꢆ
2
",
2
",
2
",
2
",
2
Metering Valve A
Metering Valve B
Pump A
Metering
Valves
ꢁ
ꢁ
ꢈ
ꢈ
ꢇ
ꢄ
ꢄ
ꢆ
ꢊ
ꢊ
ꢇ
ꢆ
ꢋ
ꢋ
Air Motors
ꢃ
ꢃ
ꢇ
ꢆ
Pump B
ꢀꢉ
ꢀꢀ
ꢀꢂ
ꢀꢉ
ꢀꢀ
ꢀꢂ
",
*ꢁ
ꢀꢋ
ꢀꢊ
ꢀꢄ
ꢀꢈ
ꢀꢁ
ꢀꢅ
ꢀꢂ
ꢀꢀ
ꢀꢉ
ꢃ
ꢀꢋ
ꢀꢊ
ꢀꢄ
ꢀꢈ
ꢀꢁ
ꢀꢅ
ꢀꢂ
ꢀꢀ
ꢀꢉ
ꢃ
3
ꢅ
ꢄ
ꢀ
ꢁ
ꢂ
ꢈ
7
",ꢆ7
2
",ꢆ2
'
Sensor
243678
B
ꢋ
ꢋ
",ꢆ'
ꢊ
ꢊ
ꢅ
ꢄ
ꢀ
ꢁ
ꢂ
ꢈ
7
",ꢆ7
2
",ꢆ2
'
ꢄ
ꢄ
Sensor
243678
ꢈ
ꢈ
ꢁ
ꢁ
ꢅ
ꢅ
ꢂ
ꢂ
A
",ꢆ'
ꢀ
ꢀ
ꢀ
3
ꢀ
ꢀ
ꢂ
ꢅ
ꢁ
ꢈ
ꢄ
ꢊ
*ꢂ
*ꢀ
Case Gnd Clip
ꢀ
ꢂ
ꢅ
ꢁ
ꢈ
ꢄ
ꢊ
2
7
",
ꢀ
ꢀ
ꢂ
ꢅ
ꢁ
ꢈ
ꢄ
*ꢀ
ꢀ
ꢂ
ꢅ
ꢁ
ꢈ
ꢄ
ꢀ
ꢂ
ꢅ
ꢁ
ꢈ
ꢄ
Key:
BL Black
BR Brown
BL-GBlack with green
BL-RBlack with red
BL-WBlack with white
Green
GNDGround
Red
S
W
Shield
White
G
R
28
309518P
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Electrical Schematic
304
301
Air Input
Power
Supply
Barrier
Board
Power
Supply
Front Panel
Alarm +
Alarm COM
Comport Pin
Front View
Alarm 15A849
COM Port
RS232
ꢀ
Connector
ꢀ
ꢂ
ꢅ
ꢂ
ꢅ
2
7
",
48
28
'.$
Start
Light
ꢅ
ꢁ
"
!
Start/Stop
Switch
15A851
'.$
Stop
Display Board
245706
*ꢂ
ꢀ
ꢂ
ꢅ
ꢁ
ꢈ
ꢀ
ꢂ
ꢅ
ꢁ
ꢈ
2
7
"2
'
Key
ꢀ
ꢂ
ꢀ
ꢂ
ꢀ
ꢂ
Switch
15A852
ꢀ
ꢂ
ꢅ
ꢁ
ꢈ
ꢄ
",
*ꢅ
ꢀ
ꢂ
ꢅ
ꢀ
ꢂ
ꢅ
",
2
'
'.$
ꢂ
ꢀ
ꢋ
Key Switch
momentary
ꢊ
ꢇ
ꢆ
309518P
29
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Pneumatic/Sensor Connections
Pneumatic/Sensor Connections
A
B
C
D
F
H
J
G
E
L
K
Key:
A
B
C
D
E
F
G
H
J
Pump A Air
Pump B Air
Pump A Pilot Air
Pump B Pilot Air
Air Supply
Metering Valve A - CLOSE
Metering Valve A - OPEN
Metering Valve B- CLOSE
Metering Valve B- OPEN
Sensor A Cable
K
L
Sensor B Cable
FIG. 25
309518P
31
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Parts
Parts
Xtreme Mix Proportioner
DETAIL D
Ref. 6
47
(side B) 45
(side A) 46
86
Ref. 3, 4, 5
Ref. 6
See
DETAIL B
2
47
49
TI2321A
Parts for
Model 248842
11,12,13
43
See DETAIL
A & D
24
25
Ref. 6
47
42
7
Ref. 62
1
See
DETAIL C
(side B) 45
(side A) 46
*26
26
Ref. 71
63
*25
*87
66
*87
*8
17,29,37,
38,40
47
49
*59
97**
97b
97c
97d
*60
*33
90**
*30
81
64 68 65
97a
97e
(blue) *16
(green) *78
80
TI2321B
86
TI2317A
32
309518P
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Parts
Xtreme Mix Proportioner
Part Number Table
Approved for Non-hazardous Location
Xtreme
Mix
Metering
Valve (6)
Gun
(15)
Hose
(20)
Coupling
(56)
Relief
Valve (79)
Tube
(45)
Tube
(46)
Pump (2)
233863
233864
233865
233866
233867
233868
233869
233870
248842
249274 (45:1)
249275 (56:1)
249276 (68:1)
249277 (80:1)
249278 (45:1)
249279 (56:1)
249280 (68:1)
249281 (80:1)
249276 (68:1)
245824
245824
245824
245824
245824
245824
245824
245824
248843
XTR704
XTR704
XTR704
XTR704
XTR704
XTR704
XTR704
XTR704
none
H53850
H53850
H73850
H73850
H53850
H53850
H73850
H73850
none
15B729
15B729
15B729
15B729
15B729
15B729
15B729
15B729
none
113498
113498
113498
116643
113498
113498
113498
116643
108124
15A914 15A915
15A914 15A915
15A914 15A915
15A914 15A915
15A914 15A915
15A914 15A915
15A914 15A915
15A914 15A915
15A914 15A915
309518P
33
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Parts
Ref.
Ref.
No. Part No. Description
Qty.
No. Part No. Description
Qty.
38
39
40‡
42
43
44
45
100721 PLUG; 1/4 nptf
101566 LOCKNUT, not shown
PLUG
15B281 COVER
112774 SCREW, 1/4-20
103196 SCREW, #8-32 x 0.44 in.
1
1
1
1
6
6
1
1
2
245997 CART
1
2
see table,
PUMP; see manual 311762 for
parts
3
245803 PNEUMATIC CONTROL; parts
page 37
245802 PUMP AIR MANIFOLD; parts page
1
4
5
1
1
see table,
TUBE, pump B
see table,
46
47
48
TUBE, pump A
1
4
6
245824 METERING VALVE MANIFOLD;
1
1
see table,
parts page 41
117344 FITTING; 1/2 npt(m) x 5/8 in.
(16 mm) tube
100560 SCREW; 3/8-16 UNC x 4.75 in.
248843 METERING VALVE MANIFOLD;
1 or
2**
2
see table,
248842 only
7
8*
9
117628 AIR FILTER; 3/4 npt; 40 micron
244524 GROUND WIRE, with clamp; not
shown
551390 BEAKER
2
1
1
49
56*
158683 ELBOW, 90°; 1/2 npt
15B729
see table,
COUPLING
1
57*
58*
H72506 HOSE, fluid; nylon; 1/4 in. (6.3 mm)
ID; 1/4 npsm(fbe); 6 ft (1.8 m)
243832 KIT, siphon hose; 1/2 npsm(f) x 1/2
npt; not shown
117525 ELBOW, 90°; 1/2 npt
108143 STRAINER; 16 mesh
C19660 FITTING; 1-1/4 x 1/2 npt; not
shown
246127 CART HANDLE
15B161 AXLE
113362 WHEEL
113436 RETAINING RING
15B755 SPACER
114552 CAP
154628 WASHER
054139 TUBE, nylon; 1.5 ft. (0.46 m);
0.5 in. OD; not shown
101242 RETAINING RING
113807 WHEEL
15A912 AXLE, vertical
1
1
10*
11
2
2
2
4
1
15A847 MAGNET HOLDER
12‡ 15A814 MAGNET; 2.7 ft. (0.8 m)
13
15*
104092 SCREW; 10-24 UNC
59*
60*
61*
1
1
2
see table,
SPRAY GUN, see manual 312145
16*
17
18*
234017 FLUID RESERVOIR, blue
C19041 WASHER
214954 AIR HOSE; 3/4 x 1/2 npt; 2.75 ft.
(0.84 m); not shown
2
1
2
62
63
64
65
66
67
68
70
1
1
2
3
2
20*
H73850 HOSE, fluid; nylon; 3/8 in. (10 mm)
1
1
see table,
ID; 3/8 npsm(fbe); 50 ft (15.2 m)
long
H53850 HOSE, fluid; nylon; 3/8 in. (10 mm)
1
3
see table,
ID; 3/8 npsm(fbe); 50 ft (15.2 m)
long
★
21*
22*
24
25
26
27*
28*
29
30*
31
511352 STATIC MIXER
1
1
8
150287 COUPLING; 3/8 npt
100004 SCREW; 3/8 UNC
100133 LOCKWASHER
100131 NUT; 3/8-16 UNC
115348 SCREW; 3/8-16 UNC x 2.75 in.
15A776 PLATE
207675 AIR MANIFOLD
112580 SWIVEL, 90°; 1.25 npsm
100016 LOCKWASHER
72
73
74
75
76
77
78*
79
2
2
1
1
4
2
1
1
†15
†15
2
15A913 AXLE, horizontal
191824 WASHER
1
1
2
4
4
2
15A892 BEARING, brass
234097 FLUID RESERVOIR; green
113498 SAFETY RELIEF VALVE; 110 psi
see table,
(0.8 MPa, 8 bar)
32
33*
100015 NUT; 1/4-20 UNC
117366 SHUTOFF VALVE, 3-way; 1/2 npt
116643 SAFETY RELIEF VALVE; 90 psi
1
1
see table,
(0.6 MPa, 6.2 bar)
34‡ C12508 TUBE, nylon; 3/8 in. (9.5 mm) OD;
1 ft. (0.3 m); not shown
35‡ 054753 TUBE, nylon, black; 0.156 in.
(4 mm) OD; 6 ft. (1.8 m); not shown
★
108124 SAFETY RELIEF VALVE; 75 psi
★
see table,
(0.5 MPa, 5.2 bar)
36
37
15A845 LABEL, air supply pressure
100139 PLUG; 1/8 nptf
1
1
80
81
124450 CLAMP
C20490 FITTING
2
2
34
309518P
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Parts
Ref.
Ref.
No. Part No. Description
Qty.
No. Part No. Description
Qty.
83
84*
116746 FITTING; 1/8 npt x 1/4 in. (6.4 mm)
tube; see page 41
116750 TUBE, nylon; 5 in. (12.7 cm); parts
page 41
193185 LABEL, warning
2
2
97b 160022 • UNION; 1 in. npt(m) x 1 in.
npsm(m)
97c 110878 • STRAINER; 1 in.
97d 118464 • BALL VALVE; 1 in.
97e 202965 • UNION; 1 in. npt(m) x 3/4
npsm(f)
1
1
1
1
85*
2
86
87*
88*
3
2
4
2
2
15C567 BRACKET, hopper
100132 WASHER, flat; not shown
98
99
100451 COUPLING
115671 FITTING, (m) 1/8 npt
1
1
2ft.
90** 116401 ELBOW, 90°
97** 249024 STRAINER KIT; 500 psi (3.4 MPa,
34 bar) maximum working pres-
100 054123 TUBE, draining
*
Not included with Model 248842.
** Included with Model 248842 only.
sure; includes items 97a-97e
‡
★
Not available for order from Graco.
Order length needed from distributor.
97a C20490 • NIPPLE, hex; 1 in. npt
2
Hose and Gun
*15
*56
*21
*22
20*
*57
309518P
35
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Parts
Pneumatic Control 245803
Item 3, page 33
a
d
b
a
k
p
n
f
h
g
e
e
f
c
303
b
304
311
m
j
s
315
321
f
c
t
320
306
302
301
313
312
317
TO SOLENOIDS
306r
FROM TURBINE
Ref. 304
POWER
307
TO PUMP POSITION
314
SENSORS
304
305
MOTOR A
MOTOR B
310
309
B PUMP
TI2303A
REF
310
313
316
306
A PUMP
309518P
37
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Parts
Pneumatic Control 245803
Ref.
Ref.
No. Part No. Description
Qty.
No. Part No. Description
Qty.
315 15B090 GROUNDING WIRE, door
316 15B056 LABEL, air connections
317 111307 LOCKWASHER
320 118132 LOCKWASHER, terminal
321 118129 SPACER, 8-32 UNC x 5 in. (127
mm)
1
1
1
1
1
301 245705 CIRCUIT BOARD
301a 15C318 FUSE, circuit board
302‡
303‡
304** 245854 ALTERNATOR MODULE; includes
items 304a-304e
1
1
4
1
1
SCREW; 8-32 UNC
COVER
304a 193154 • GASKET
1
1
2
4
1
2
1
IS = intrinsically safe
304b 15A853 • WIRE HARNESS
304c 111225 • TUBE FITTING; 90°
304d 114380 • SCREW; M5 x 25
304e 249254 • TURBINE ALTERNATOR
** Alternator bearing repair kit 223688 available.
‡
Not available for order from Graco.
Order length needed from distributor.
★
305‡
306‡
LOCKNUT; 8-32 UNC
SOLENOID MODULE, IS; includes
items 306a-306t
306a 15A822 • MANIFOLD
306b 117356 • VALVE, 12 VDC, IS
306c 114263 • FITTING; 1/8 npt x 5/32 in.
(4 mm) tube
1
4
6
306d‡
• NIPPLE; 1/4 npt
1
1
3
306e 115243 • AIR REGULATOR; 1/4 npt
306f 115841 • ELBOW, swivel; 1/4 npt x 3/8 in.
(9.5 mm) tube
306g 160701 • ELBOW, street; 1/8 npt(m x f)
306h 108190 • GAUGE,
1
1
1
1
5
1
306j‡
306k‡
306n‡
• GASKET, neoprene
• GASKET, neoprene
• PLUG, pipe; 1/8-27 ptf
306p 114128 • ELBOW; 1/4 npt x 1/2 in. (13
mm) tube
306q† 112512 • WIRE FERRULE, orange (not
shown)
8
306r 117369 • CONNECTOR, 12 position
306s 150278 • ADAPTER, 1/4 x 1/8 npt
306t 117480 • SAFETY RELIEF VALVE, 26 psi
(179 kPa, 1.8 bar)
1
1
1
307 15A800 GASKET, neoprene
1
2
309‡
SCREW; M5 x 10
310 C12508 TUBE, poly-flo; 3/8 in. OD; 1 ft.
(3 m)
★
311‡
NUT, KEPS; #10-24
1
1
1
1
312 104029 GROUNDING STUD
313 15A849 WIRE HARNESS, alarm
314 117442 CONNECTOR, 18 position
38
309518P
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Parts
User Interface 245804
Item 4, page 33
414,
415
Ref.
407
Ref.
403
Ref.
416
Ref. 407
410
411
404
401
Ref.
406
15A804
416
407
Back View
406
413
418
412
Ref. 405
405,419
409
15A806
Ref. 403
403
TI2307A, TI2308A
Ref.
No. Part No. Description
414‡ MOUNT
415‡ 102478 STRAP
416 15A854 WIRE HARNESS, display
418‡ WASHER
419 107232 SET SCREW
‡ Not available for order from Graco.
* Alarm Code Labels
Ref.
No. Part No. Description
401‡ COVER
403 15A851 WIRE HARNESS, start/stop
404 15A801 GASKET
405 15C335 KNOB
406 15A850 WIRE HARNESS, data port
407 15A852 WIRE HARNESS, key switch
Qty.
Qty.
3
3
1
4
1
1
1
1
1
1
1
1
1
2
1
4
409*
410 245706 CIRCUIT BOARD
411‡ SCREW; 4-40
LABEL, alarm code
Item 409, English provided. To order other languages:
Part No. Languages
412 15A856 DISPLAY PANEL
413‡ 514619 NUT; 4-40
15B843
15B844
Chinese, Finnish, Portuguese, Greek, Swedish, Italian
English, Spanish, French, German, Korean, Japanese
309518P
39
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Parts
Pump Air Manifold 245802
Item 5, page 33
Ref.
520
516
No. Part No. Description
Qty.
507 117332 REGULATOR
1
1
1
1
1
3
2
2
2
1
1
1
3
501
523
508 100840 ELBOW; 1/4 npt
510 15A819 MANIFOLD BLOCK
511 160032 NIPPLE; 3/4 npt
512 117346 SHUTOFF VALVE, vented
513 117364 O-RING, nitrile
514 108849 SCREW; 1/4-20 UNC
515 15B554 HOSE; 3/4 npt; 4 ft. (1.2 m)
516 100549 ELBOW, 90°; 3/4 npt
517 165198 NIPPLE; 1/4 x 3/8 npt
518 119644 FILTER; 3/8 npt; 5 micron
519 114316 ELBOW, swivel; 3/8 npt
520 114151 ELBOW, swivel; 1/8 npt x 5/32 in.
(4 mm) tube
521 100721 PLUG; 1/4-18 nptf
522 512912 MUFFLER; 1/2 npt
523 100896 BUSHING; 3/4 x 1/2 npt
515
502
522
504
505
504
506
503
513
507
527
2
2
2
1
524
508
524 113498 SAFETY RELIEF VALVE; 110 psi
(0.8 MPa, 8 bar)
525 117443 STANDOFF, aluminum, 8-32 UNC
526 240900 HOSE; 3/4 npt; 2.5 ft. (0.76 m)
527 158962 ELBOW, 1/8 (m) x 1/4 (f)
528 113911 GAUGE, 1/8, air
513
2
1
1
1
519
528
521
1
518
517
510
511
514
503
525
512
526
TI2295A
1
100 psi (0.7 MPa, 7 bar) setting.
Ref.
No. Part No. Description
Qty.
501 C59752 VALVE, 3-way
502 108307 ELBOW; 3/4 npt
503 101689 PRESSURE GAUGE
504 112166 SCREW; 1/4-20 UNC
505 15A820 MANIFOLD
2
2
2
4
1
1
506 15A821 PLATE, direction
40
309518P
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Parts
Metering Valve Manifold 245824
Item 6, page 34
601
Ref.
No. Part No. Description
Qty.
606 245861 SHUTOFF VALVE; see manual
306861
611 245860 SHUTOFF VALVE; see manual
306861
2
1
83c
83h
83g
83d
83f
83b
83e
83a
83
1
1
606 (side A)
611 (side B)
Metering Valve Manifold 248843
Item 6, page 34
Ref.
No. Part No. Description
Qty.
*84
*85
606 245861 SHUTOFF VALVE; see manual
306861
607b 249406 FLUID MANIFOLD, kit; see right
611 245860 SHUTOFF VALVE; see manual
306861
2
1
607a
1
1
617
Sampling Valve 245143
Item 83, page 35
610
Ref.
No. Part No. Description
Qty.
612
613
83a 245110 KNOB
83b 197681 HOUSING
83c 197332 SEAT
83d 107536 BALL, carbide
83e 110082 RETAINING RING
1
1
1
1
1
2
1
1
614
618
615
616
TI2298A
607b
*
83f
111457 O-RING, PTFE
83g 183548 SEAT
83h 187060 GASKET
Repair Kit 249406
Ref.
No. Part No. Description
Qty.
610 15E725 FLUID MANIFOLD
612 116343 GROUND SCREW
613 111307 LOCK WASHER
1
2
2
2
1
1
1
1
614 101754 PLUG, pipe
615 117502 REDUCER; #5 x #8 JIC
616 117556 NIPPLE; #8 JIC x 1/2 npt
617 117557 NIPPLE; #10 JIC x1/2 npt
618 117677 REDUCER, #6 x #10 JIC
309518P
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Parts
Metering Valve 245846
621
622
627
Item 601, page 41
*† 637
639*†
*† 634
*†638
626
*† 632
631
628
623
636
▲ 629
*† 633
† 635
630†
645*†
644†
645*†
624
646
*† 643
625
647
621
TI2299A
Ref.
Ref.
No. Part No. Description
Qty.
No. Part No. Description
Qty.
637*† 117334 V-PACKING, UHMWPE
638*† 189901 GLAND, male
639*† 117335 V-PACKING, leather
643*† 111959 O-RING, buna-n
644† 15A830 SEAT
645*† 15T260 O-RING, fluoroelastomer
646 15A832 SEAT HOUSING
647 102637 SCREW; 3/8 UNC-2A
6
1
5
1
1
2
1
4
621 598140 ELBOW, 1/8 npt(m) x 5/32 in.
(4 mm) tube
622‡ 15A840 VALVE CAP
623‡ 15A841 PISTON
624‡ 15A839 CYLINDER
625 15B545 PISTON ROD
626 15A834 TIE ROD
627 15A835 PACKING NUT
628 15A833 INLET HOUSING
629▲ 180233 WARNING LABEL
630† 245850 FLUID NEEDLE
631 111040 LOCKNUT, nylon; 5/16 UNC-3B
632*† 117336 O-RING, nitrile
633*† 117370 O-RING, nitrile
634*† 117337 O-RING, nitrile
635† 109141 SPRING
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
*
Parts included in kit 234098.
†
‡
Parts included in kit 234131.
Not available for order from Graco.
Replacement Warning labels available at no cost.
▲
636 102040 LOCKNUT; 1/4 UNC
42
309518P
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Parts
Fluid Manifold 245833
Item 607a, page 41
676
675
669
674
665
670
668
661
*662
*663
*665
*664
*665
*666
*667
671
TI2304A
Ref.
No. Part No. Description
Qty.
661 15A823 PLUG
662* 107098 O-RING, PTFE
663* 107313 O-RING, PTFE
2
2
2
2
5
2
2
4
1
1
1
2
2
1
664*
665* 103341 O-RING, PTFE
666* BALL, metallic
667* 117333 SPRING
SEAT
668
PLUG; 3/8 npt
669 15A825 PIPE, outlet
670 192977 PIPE, center
671‡
HOUSING
674 111307 LOCKWASHER
675 116343 GROUND SCREW,; M5 x 0.8
676 159239 NIPPLE; 3/8 x 1/2 npt
*
Parts included in kit 234100.
‡
Not available for order from Graco.
309518P
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Parts
Sensor 245825
Item 7, page 33
716†
712†
704†
703†
720†
715
†714
†701
710*
709*
702*
1
†707
705*
719*
713*
721*
†706
†708
711*
TI2301A
Ref.
No. Part No. Description
Ref.
Qty.
No. Part No. Description
Qty.
713* 117569 FITTING; 3/8 npt x 5/16 in. conduit
714† 154741 O-RING, buna-n
715 245831 BRACKET
2
1
1
1
2
701† 196280 CAP
1
1
1
2
1
1
1
1
1
1
2
1
702* 15A818 COVER
703† 243500 BOARD
704† 115925 SPACER
705* 117331 CABLE
706† 115917 SENSOR
707† 110004 O-RING, PTFE
708† 196289 CAP
709* 116024 TAB TERMINAL
710* 101855 SCREW; 4-24 UNC
711* 112546 SCREW; 4-40 taptite
712† 15A817 NUT; 1/8 npt
716† 104765 PLUG; 18-27 ptf
719* 117586 LOCKNUT; 3/8-18 npt
720† C20272 O-RING; fluoroelastomer
721* 117582 CONDUIT, 5 ft. (1.5 m); not shown
1
★
*
Parts included in kit 246345.
†
★
Parts included in kit 246344.
Order length needed from distributor.
Calibration label.
1
44
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Technical Data
Technical Data
Mix ratio range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0:1-10:1 (in 0.1 increments)
Ratio tolerance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . +/- 5%
Flow rates
Minimum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 qt./min. (0.95 liter/min.)*
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 gal./min. (11.4 liter/min.)
Fluid viscosity range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-20,000 cps (heavier viscosities can be mixed with use
of optional heaters, heated hoses, and hardware)
Fluid filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mesh, (238 micron) standard on pump outlets (Filter
assembly not included on models 248831, 248832,
248833, and 248834)
Air inlet
Model 248842. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt(m)
All Other Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt(f)
Model 248842: Fluid inlet . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm union in 1 in. npt(f) ball valve
Maximum fluid working pressure
45:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500 psi (31 MPa, 310 bar)
56:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5600 psi (38.6 MPa, 386 bar)
68:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6800 psi (46.9 MPa, 469 bar)
68:1 Model 248842 only. . . . . . . . . . . . . . . . . . . . . . . 5000 psi (34.5 MPa, 345 bar)
80:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7250 psi (50 MPa, 500 bar)
Air supply pressure range. . . . . . . . . . . . . . . . . . . . . . . . . 50-110 psi (345-800 kPa, 3.5-8 bar)
Model 248842: Maximum fluid feed pressure. . . . . . . . . . 500 psi (3.5 MPa, 35 bar)
3
Maximum air consumption at 100 psi (0.7 MPa, 7 bar) in cfm (m /min.)
45:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 (3.1)
56:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 (3.5)
68:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 (4.4)
80:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 (5.1)
Ambient temperature range
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-130° F (0-54° C)
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160° F (–1-71° C)
Environmental Conditions Rating . . . . . . . . . . . . . . . . . . . Indoor/outdoor use
Altitude up to 4000 meters
Maximum relative humidity to 99% up to 54° C
Pollution degree (11)
Installation category (2)
Sound pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 dBA at 100 psi (0.7 MPa, 7 bar)
Wetted parts
Suction tubes (if used) . . . . . . . . . . . . . . . . . . . . . . . . aluminum
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . carbon steel, alloy steel, 303, 440 & 17-4ph grades stain-
less steel, zinc and nickel plating, ductile iron, tungsten
carbide, PTFE, leather
Metering Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . carbon steel, zinc plating, carbide, polyethylene, leather
Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . carbon steel, zinc plating, carbide, 302 stainless steel
Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stainless steel
Spray gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See gun manual
309518P
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Technical Data
PC Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-232
Dimensions
Cart model (width x height x diameter) . . . . . . . . . . . 33 in. wide x 64.53 in. high x 44.5 in. deep
(83.8 x 163.9 x 113 cm)
Weight (cart, without hose and gun) . . . . . . . . . . . . . 625 lbs. (285 kg)
*
Minimum flow rate is dependent on the material being sprayed and mixing capability. Test your material for spe-
cific flow rate.
46
309518P
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Technical Data
309518P
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Graco Standard Warranty
Graco 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 CUSTOMERS
The 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 Information
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
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 309518
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2002, Graco Inc. is registered to ISO 9001
Revised 01/2011
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