Graco Washer 309518P User Manual

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  
components may impair intrinsic safety. See page 5.  
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.  
309518P  
3
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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  
5
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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
309518P  
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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  
Follow Pressure Relief Procedure when you stop  
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
309518P  
7
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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  
the center ring on a hoist. See FIG. 1. Carefully lift the  
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
309518P  
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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.  
1. Follow Pressure Relief Procedure, page 7. Engage  
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.  
3. Follow Pressure Relief Procedure, page 7.  
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.  
309518P  
9
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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  
309518P  
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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.  
If problem still persists, see Troubleshooting, page  
12.  
309518P  
11  
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Troubleshooting  
Troubleshooting  
WARNING  
If an error code displays, see page 15.  
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.  
Page 16.  
Turbine air regulator set too low.  
Turbine alternator failure.  
Adjust to proper setting.  
Repair or replace turbine. Page 20.  
Power supply not connected to main  
board.  
Check power connections to main board.  
See Electrical Schematic, page 28.  
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  
Replace valve(s). Page 22.  
Service or replace valve(s). Page 24.  
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  
necessary. See page 19.  
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  
309518P  
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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.  
Test pump. Page 10.  
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.  
Clean. Replace element(s). See page 16.  
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.)  
Replace bearings. Page 20.  
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.  
See Electrical Schematic, page 28.  
Faulty stop switch or wiring harness.  
Check stop switch and wiring harness  
continuity; stop switch is normally closed  
circuit. See Electrical Schematic, page  
Bad I/O port on main board.  
Replace board. Page 17.  
Fluid valves leaking.  
Loose or worn packings.  
Tighten packing nut. If leak continues,  
replace packings. Page 24.  
309518P  
13  
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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  
309518P  
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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.  
Page 27.  
Sensor Error B*  
Controller Error*  
Loose cable, failed sensor or cable.  
Page 27.  
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.  
Metering valve A leak. Page 24.  
Empty B fluid reservoir.  
B dose too great.  
Metering valve B leak. Page 24.  
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.  
309518P  
15  
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Repair  
Repair  
Follow Shutdown procedure, page 9, if service time  
may exceed pot life time, before servicing fluid compo-  
nents, and before transporting equipment to a service  
area.  
3. Unscrew filter bowl. FIG. 4.  
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  
2. Unscrew filter bowl. FIG. 5.  
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.  
2. Remove air manifold cover (42). FIG. 3.  
4. Remove and replace element. FIG. 6.  
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.  
2. Remove air manifold cover (42). FIG. 3, page 16.  
3. Remove four nuts (32) and open user interface  
cover (4). FIG. 7–FIG. 8.  
FIG. 9  
32  
3. Install new chip (beveled corner down).  
4. Reassemble.  
5. Recalibrate main circuit board. See page 19.  
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
4. Reassemble. Refer to Electrical Schematic, page  
28.  
FIG. 8  
5. Recalibrate main circuit board. See page 19.  
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  
309518P  
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Repair  
Replacing Display Circuit Board  
411  
CAUTION  
To avoid damaging circuit board, wear a grounding  
strap.  
410  
1. Remove User Interface cover. See page 17.  
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  
6. Reassemble. Refer to Electrical Schematic, page  
28.  
B
1
405  
1
Align knob to allow for turning to all 6 settings.  
FIG. 11  
18  
309518P  
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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  
(refer to page 15).  
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  
. FIG. 12. Hold down  
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.  
309518P  
19  
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Repair  
Pneumatic Control  
Alternator Repair  
Turbine Alternator Repair Kit 223688 is available to  
replace turbine bearings.  
305  
304  
1. Remove User Interface cover. See page 17.  
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  
2. Disconnect power supply wires (P). 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  
housings. FIG. 15.  
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).  
8. Reassemble. Refer to Electrical Schematic, page  
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  
309518P  
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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-  
nector (306r) from main board. FIG. 13, page 20.  
1. Remove User Interface cover. See page 17.  
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).  
7. Reassemble. Refer to Electrical Schematic, page  
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 +,  
black –). Refer to Electrical Schematic, page 28.  
1. Remove User Interface cover. See page 17.  
2. Disconnect alarm wires from main board.  
3. Unscrew alarm (313) and replace. FIG. 16.  
Replacing Alternator Regulator  
1. Remove User Interface cover. See page 17.  
4. Reassemble. Refer to Electrical Schematic, page  
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  
309518P  
21  
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Repair  
Pump Air Manifold  
1. Close main air shutoff valve on air supply line and  
on unit.  
5
2. Pull off regulator knob (R). FIG. 17.  
3. Remove two screws (44).  
R
4. Disconnect two hoses (515) from pump motors.  
5. Replace parts as needed. See page 40.  
6. Reassemble.  
515  
44  
FIG. 17  
22  
309518P  
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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
6308  
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.  
1. Remove metering valve. See page 24.  
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  
unit. FIG. 22.  
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.  
7. Reassemble and mount sensor. Refer to Electrical  
Schematic, page 28.  
FIG. 23  
Mount sensor as close to magnet as possible  
without touching it.  
8. Recalibrate main circuit board. See page 19.  
Displacement Pump  
2. Disconnect 90° swivel (30) from pump lower. Refer  
to page 32.  
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  
ꢀꢈ6$#  
#/-  
2
",  
Jumper (15V)  
Main Circuit  
Board  
245705  
*ꢈ  
Solenoids  
2
",  
2
",  
2
",  
2
",  
2
Metering Valve A  
Metering Valve B  
Pump A  
Metering  
Valves  
Air Motors  
Pump B  
ꢀꢉ  
ꢀꢀ  
ꢀꢂ  
ꢀꢉ  
ꢀꢀ  
ꢀꢂ  
",  
*ꢁ  
ꢀꢋ  
ꢀꢊ  
ꢀꢄ  
ꢀꢈ  
ꢀꢁ  
ꢀꢅ  
ꢀꢂ  
ꢀꢀ  
ꢀꢉ  
ꢀꢋ  
ꢀꢊ  
ꢀꢄ  
ꢀꢈ  
ꢀꢁ  
ꢀꢅ  
ꢀꢂ  
ꢀꢀ  
ꢀꢉ  
3
7
",ꢆ7  
2
",ꢆ2  
'
Sensor  
243678  
B
",ꢆ'  
7
",ꢆ7  
2
",ꢆ2  
'
Sensor  
243678  
A
",ꢆ'  
3
*ꢂ  
*ꢀ  
Case Gnd Clip  
2
7
",  
*ꢀ  
Key:  
BL Black  
BR Brown  
BL-GBlack with green  
BL-RBlack with red  
BL-WBlack with white  
Green  
GNDGround  
Red  
S
W
Shield  
White  
G
R
28  
309518P  
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Electrical Schematic  
304  
301  
Air Input  
Power  
Supply  
Barrier  
Board  
Power  
Supply  
Front Panel  
Alarm +  
Alarm COM  
Comport Pin  
Front View  
Alarm 15A849  
COM Port  
RS232  
Connector  
2
7
",  
48  
28  
'.$  
Start  
Light  
"
!
Start/Stop  
Switch  
15A851  
'.$  
Stop  
Display Board  
245706  
*ꢂ  
2
7
"2  
'
Key  
Switch  
15A852  
",  
*ꢅ  
",  
2
'
'.$  
Key Switch  
momentary  
309518P  
29  
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Pneumatic Schematic  
Pneumatic Schematic  
FIG. 24  
30  
309518P  
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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  
Parts shown here and page 34 and 36.  
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  
Refer to page 3 for additional model information.  
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  
245804 USER INTERFACE; parts page 39  
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,  
parts page 41; used on model  
248842 only  
7
8*  
9
245825 SENSOR; parts page 44  
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*  
245143 SAMPLING VALVE; parts page 41  
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  
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  
5
79  
32  
31  
83, 84, 85  
36  
6
99  
98  
27  
25  
48*  
100  
25  
44  
10*  
3
4
TI2316A  
DETAIL B  
28*  
26  
Parts for  
Model 248842  
62  
48  
65  
68  
77  
67  
48  
25  
25  
72  
77  
74  
73  
75  
76  
72  
76  
26  
26  
76  
DETAIL A  
DETAIL C  
36  
309518P  
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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  
306q112512 • 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.  
601 245846 METERING VALVE; parts page 42  
606 245861 SHUTOFF VALVE; see manual  
306861  
607a 245833 FLUID MANIFOLD; parts page 43  
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  
601 245846 METERING VALVE; parts page 42  
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  
*
See page 35 for part numbers and descriptions.  
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  
41  
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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  
64415A830 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  
629180233 WARNING LABEL  
630245850 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  
635109141 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  
43  
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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  
309518P  
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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  
45  
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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  
47  
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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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