Graco 313289B, XM Plural-Component Sprayers, Repair-Parts Owner's Manual

Repair-Parts

XM Plural-Component

Sprayers

313289B

ENG

For spraying two-component epoxy and urethane protective coatings in hazardous and

non-hazardous locations.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 7 for model information and agency approvals.

See page 77 for maximum working pressure.

2

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . 9

Material Self-Ignition . . . . . . . . . . . . . . . . . . . . . . 9

Moisture Sensitivity of Isocyanates . . . . . . . . . . . 9

Components A and B . . . . . . . . . . . . . . . . . . . . 10

Changing Materials . . . . . . . . . . . . . . . . . . . . . . 10

Before Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Proper Lifting of Sprayer . . . . . . . . . . . . . . . . . . 11

Pressure Relief Procedure . . . . . . . . . . . . . . . . 12

Flush Before Using Equipment . . . . . . . . . . . . . 13

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Flush Mixed Material . . . . . . . . . . . . . . . . . . . . . 14

Empty and Flush Entire System (new sprayer or end of job) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Shutdown Entire System . . . . . . . . . . . . . . . . . . . 18

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . 18

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

View Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Diagnose Alarms . . . . . . . . . . . . . . . . . . . . . . . . 22

Clear Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Alarm Codes and Troubleshooting . . . . . . . . . . 23

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Replace Air Filter Element . . . . . . . . . . . . . . . . 29

User Interface/Control Box . . . . . . . . . . . . . . . . 30

Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Fluid Control Assembly . . . . . . . . . . . . . . . . . . . 39

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . 41

Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Fluid Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 44

Simplified Electrical Schematic, XM Sprayer with

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Detailed Electrical Schematic, XM Sprayer with

Alternator (page 1) . . . . . . . . . . . . . . . . . . . 46

Simplified Electrical Schematic, XM Sprayer with

Wall Power . . . . . . . . . . . . . . . . . . . . . . . . . 48

Detailed Electrical Schematic, XM Sprayer with Wall

Power (page 1) . . . . . . . . . . . . . . . . . . . . . . 50

Junction Box Wiring Schematics . . . . . . . . . . . . . 52

Fluid Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Hopper Heaters . . . . . . . . . . . . . . . . . . . . . . . . . 53

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Control Box (255771) Parts . . . . . . . . . . . . . . . . 62

Control Box Power Supply Options . . . . . . . . . . 64

Air Controls Module (255761) Parts . . . . . . . . . 66

Junction Box (256540) Parts . . . . . . . . . . . . . . . 67

Fluid Control Assembly Parts . . . . . . . . . . . . . . 68

Air Inlet Manifold (255762) Parts . . . . . . . . . . . . 69

Alternator Module (255728) Parts . . . . . . . . . . . 70

Repair and Spare Parts Reference . . . . . . . . . . 71

Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . 72

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

System Dimensions without Hoppers . . . . . . . . 74

System Dimensions with Hoppers . . . . . . . . . . . 75

System Dimensions with Hoppers . . . . . . . . . . . 76

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 78

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 78

313289B

Related Manuals

Manuals are available at www.graco.com.

Component Manuals in U.S. English:

312769

312794

406699

406739

406740

406690

406691

313258

313259

312770

312749

313293

313342

313343

Manual

313289

313292

311762

311328

312747

309524

312145

Description

XM Plural-Component Sprayers

Repair-Parts

XM Plural-Component OEM Sprayers

Instructions-Parts

Xtreme

®

Displacement Pumps

Instructions-Parts

NXT

™

Air Motor Instructions-Parts

Double Wall Hopper Kit

Instructions-Parts

Viscon

®

HP Heater Instructions-Parts

XTR

™

5 and XTR

™

7 Spray Guns

Instructions-Parts

Feed Pump and Agitator Kits

Instructions-Parts

Merkur

®

Pump Assembly

Instructions-Parts

7-Gallon Hopper Installation Kit

Instructions-Parts

Desiccant Kit Instructions-Parts

Level Sensor Adapter Kit

Instructions-Parts

Caster Kit Instructions-Parts

Hose Rack Kit Instructions-Parts

Electric Heated Hose Power Supply Kit

Instructions-Parts

Hopper or Hose Heat Circulation Kit

Instructions-Parts

Lower Strainer and Valve Kit

Instructions-Parts

XM Mix Manifold Kit

Instructions-Parts

Alternator Conversion Kits

Instructions-Parts

Dosing Valve Repair Kit

Instructions-Parts

High Flow Severe Duty Shutoff Check

Valve Repair Kit Instructions-Parts

313289B

Related Manuals

3

4

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

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 all equipment in the 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 working fire extinguisher in the work area.

• Do not connect USB device in explosive atmospheres.

SPECIAL CONDITIONS FOR SAFE USE

• To prevent the risk of electrostatic sparking, the equipment’s non-metallic parts must be cleaned with only a damp cloth.

• Refer to the Viscon HP Heater manual for special conditions for safe use.

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 regulations.

313289B

313289B

Warnings

WARNING

INTRINSIC SAFETY

Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations and the following safety requirements.

• Only models with model number XM_D_ _ or XM_E_ _, and packaged models with part numbers ending in 00-13, 17-23, 27-29, 31, utilizing the air-driven alternator are approved for installation in a

Hazardous (explosive atmosphere) Location - see Approvals:, page 8. Only the models stated

above meet all local safety fire codes including NFPA 33, NEC 500 and 516, and OSHA 1910.107.

To help prevent fire and explosion:

• Do not install equipment approved only for a non-hazardous location in a hazardous location.

See model ID label for intrinsic safety rating of your model.

• Do not substitute system components as this may impair intrinsic safety.

• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic

Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit from the hazardous area when troubleshooting.

• Do not connect, download, or remove USB device unless unit is removed from the hazardous (explosive atmosphere) location.

• If explosion-proof heaters are used, ensure wiring, wiring connections, switches, and electrical distribution panel all meet flame-proof (explosion-proof) requirements.

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.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

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.

5

6

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical 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. For complete information about your material, request MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read 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.

• Always wear impervious gloves when spraying or cleaning equipment.

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.

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

313289B

Models

Models

XM sprayers are not approved for use in hazardous locations unless the base model, all accessories, all kits, and all wiring meet local, state, and national codes.

Check the identification plate (ID) for the 6-digit part number of the sprayer. Use the following matrix to define the construction of the sprayer, based on the six digits. For example, Part XM1A00 represents an XM Plural-Component sprayer (XM); 5200 psi pump set with pump filters (1); wall power supply, no heaters, no junction box, and is not approved for hazardous areas (A); with no additional kits (00).

NOTE:

Some configurations in the following matrix cannot be built. See the Product Selection Guide for available systems. If option(s) for third, fourth, fifth, and sixth digits is blank, the option(s) is not included with that particular configuration.

To order replacement parts, see Parts section in this manual. The digits in the matrix do not correspond to the Ref.

Nos. in the Parts drawings and lists.

XM

First and

Second

Digits

XM

(plural component sprayer mounted on a frame)

1

2

3

Pump Set

(hose/gun)

5200 psi

5200 psi

6300 psi

4 6300 psi

5 5200 psi

6 5200 psi

7 6300 psi

8 6300 psi

1

Third Digit

System Choice

(See Table 1 for lower models)

Pump

Filters









Remote

Manifold









A

Fourth Digit

00

Fifth and

Sixth

Digits

A

B

D

E

Control

Box

Wall Power

Supply

Wall Power

Supply

IS/

Alternator

IS/

Alternator

Fluid

Heaters



Kit Choice

Additional

Kit

Junction

Box

Location

Category



NE

NE

Approvals

(See page 8

for approvals)

CE, FM,

FM c

CE, FM,

FM c

See Table

2 for selections



EH

EH

CE, FM,

FM c, Ex

CE, FM,

FM c, Ex

Location Category Key:

NE Not for use in explosive atmospheres.

EH For use in explosive atmospheres and hazardous locations .

313289B 7

Models

Approvals:

Code

1 or 5

2 or 6

3 or 7

4 or 8

Intrinsically safe for Class I, Div 1, Group D, T2

Class I, Division 1, Group D, T2

Ta = 0°C to 54°C

FM09ATEX0015X

II 2 G

Ex d ia px IIA T2 Tamb = 0ºC to 54ºC

See Special Conditions for Safe Use in Warnings, page 4.

Table 1: Lower Models and Corresponding Identification Codes

System Pressure

(MPa, bar)

5200 psi (35, 350)

5200 psi (35, 350)

6300 psi (49, 490)

6300 psi (49, 490)

Pump

Filters





A Lower

(see manual 311762)

L250C4

L250C3

L180C4

L180C3

B Lower

(see manual 311762)

L220C4

L220C3

L145C4

L145C3

2

2

2

2

2

2

1

2

1

1

1

1

1

1

25

26

27

29

19

21

23

24

30

31

14

15

16

17

00

11

13

Table 2: Additional Kits - Identification Code Index

20 Gal.

Hopper

Kit

Hopper Hopper

Heater Kit Fluid Inlet

Hopper

Universal

240V Kit Mount Kit

Twistork

Agitator

Kit

T2 Pump

Feed Kit

(on hopper)

5:1 Pump

Feed Kit

(on hopper)

7 Gal.

Hopper and

Bracket

Kit

Drum

Feed Kit

(Dual T2 and

Agitator)

Drum

Feed Kit

(Dual 5:1 and

Agitator)

Heated

Hopper/

Hose

Circulati on Kit

2

2

2

1

1

1

1

2

2

1

1

2

2

2

2

2

2

2

1

2

1

1

1

1

1

1

2

2

2

2

2

2

1

2

1

1

1

1

1

1

1

2

1

1

1

2

2

2

1

1

1

1

1

1

1

2

2

1

1

1

1

NOTE:

See Repair and Spare Parts Reference, page 71, for

more information.

See Related Manuals, page 3, for kit manual numbers.

8 313289B

Overview

Overview

XM sprayers are not approved for use in hazardous locations unless the base model, all accessories, all kits, and all wiring meet local, state, and national

codes. See Models, page 7, to determine the appro-

priate location for your particular model.

Isocyanate Hazard

Spraying materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

Read material manufacturer’s warnings and material

MSDS to know specific hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Moisture Sensitivity of

Isocyanates

Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture

(such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

NOTE:

The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the ISO lube pump reservoir filled with Graco

Throat Seal Liquid (TSL), Part 206995. The lubricant creates a barrier between the ISO and the atmosphere.

• Use moisture-proof hoses specifically designed for

ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been contaminated from the other side.

• Always park pumps when you shutdown.

• Always lubricate threaded parts with Part 217374

ISO pump oil or grease when reassembling.

Material Self-Ignition

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and material MSDS.

313289B 9

Overview

Components A and B

IMPORTANT!

Material suppliers can vary in how they refer to plural component materials.

Be aware that in this manual:

Component A refers to resin or major volume.

Component B refers to the hardener or minor volume.

NOTE:

This equipment doses the B component into the A component flow. An integration hose must always be used after the mix manifold.

Follow these recommendations for reassembly and setup:

• use at least a 3/8 in. (10 mm) x 25 ft. (7 m) hose.

• install a 24-element static mix tube after the integration hose.

Keep Components A and B Separate

NOTICE

To prevent cross-contamination of the equipment’s wetted parts, never interchange component A

(resin) and component B (hardener) parts.

Changing Materials

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers and outlet filter

after flushing. See Flush on page 14.

• Check with your material manufacturer for chemical compatibility.

• Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the A (resin) side.

NOTE:

If the amine will switch between the two sides, see

Flush on page 14.

10 313289B

Before Repair

Before Repair

Location Proper Lifting of Sprayer

XM sprayers are not approved for use in hazardous locations unless the base model, all accessories, all kits, and all wiring meet local, state, and national

codes. See Models, page 7, to determine the appro-

priate location for your particular model.

Grounding

Follow instructions to avoid serious injury or damage to equipment. Never lift with the hopper(s) filled.

Connect ground wire clamp (FG) to a true earth ground.

If wall power is used to power controls or heaters, ground electrical connection properly according to local codes.

r_xm1a00_313289_9f

Lift Using a Forklift

Power must be off. Sprayer can be raised and moved using a forklift. Carefully lift the sprayer; make sure it balances evenly.

Lift Using a Hoist

Sprayer can also be lifted and moved using a hoist. Connect a bridle swing, hooking an end to each of the air motor lift rings. Hook the center ring to a hoist Carefully lift the sprayer; make sure it balances evenly.

r_xm1a00_313289_7a1

FG

2.0 ft. (0.61 m) minimum in.

mm)

NIMUM

313289B 11

Before Repair

Pressure Relief Procedure

Follow Pressure Relief Procedure when you stop

spraying or dispensing; and before cleaning, checking, servicing, or transporting equipment.

Relieve A and B Fluid Pressure

1.

Engage trigger lock.

7.

Hold a metal part of the gun firmly to a grounded metal pail with a splash guard in place. Trigger gun to relieve pressure in material hoses.

TI1953a

8.


TI1949a

2.

Press .

3.

If fluid heaters are used, shut them off using the controls on the heater control box.

TI1949a

Relieve Pump Fluid Pressure

9.

Close mix manifold valves (AH, AJ), then open solvent flush valve (AK) on mix manifold.

4.

Shut off feed pumps, if used.

5.

Remove spray tip and clean.

6.

Disengage trigger lock.

Fluid Heater B

Fluid Heater A r_312359_313289_1a

AK

AH

AJ

Replace with illustration

312359 313289

10. Open solvent pump air control (CB). Use lowest pressure needed to flush material out of hose.

CB

12

TI1950a r_312359_313289_14

313289B

11. Disengage trigger lock.

TI1950a

12. Hold a metal part of the gun firmly to a grounded metal pail with a splash guard in place. Trigger gun to flush mixed material out of line with clean solvent.

13. Shut off solvent pump on air control panel.

14. Repeat steps 11 and 12. Then continue to step 15.

15. Close solvent flush valve (AK) on mix manifold.

Before Repair

Flush Before Using Equipment

The equipment was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the equipment with a

compatible solvent before use. See Flush on page 14.

AK

Replace with illustration

r_312359_313289_5

16. Release any residual gun pressure and engage trigger lock.

TI1949a

313289B 13

Flush

Flush

Flush Mixed Material

4.

Open solvent pump air control (CB). Pull out and slowly turn solvent pump air regulator (CG) clockwise to increase air pressure. Use lowest possible pressure.

Flush Mix Manifold

Use Solvent Pump

1.

Press

to turn off system. Follow Pressure

Relief Procedure, page 12. Engage trigger lock.

Remove spray tip.

CB

CG

4)!

TI1949a

TI1948a

2.

Close sampling valves (AE, AF) and mix manifold valves (AH, AJ).

r_312359_312359_3

5.

Disengage trigger lock. Hold a metal part of the gun firmly to a grounded metal pail with a splash guard in place.Use a pail lid with a hole in it to dispense through. Be careful to keep fingers away from the front of the gun. Trigger gun until solvent appears.

AE

AF

AK

AJ

TI195oa

6.


AH

TI1953a

TI1949a

3.

Open solvent shutoff valve (AK) at mix manifold.

14 313289B

7.

Close solvent pump air valve (CB) and solvent shutoff valve (AK) at mix manifold.

8.

Follow Pressure Relief Procedure, page 12.

9.


Flush

AK TI1949a

10. Disassemble and clean spray tip with solvent by hand. Reinstall on the gun.

313289B 15

Flush

Empty and Flush Entire System

(new sprayer or end of job)

Procedure

1.

Follow Pressure Relief Procedure, page 12, and

Flush Mixed Material, page 14, as required.

Engage trigger lock. Turn main pump air regulator

(CD) fully counter-clockwise to shut off.

NOTE:

• If system includes heaters and heated hose, turn them off and allow to cool before flushing. Do not turn on heaters until fluid lines are clear of solvent.

• Use the lowest possible pressure when flushing to avoid splashing.

• Before color change or shutdown for storage, flush at a higher flow rate and for a longer time.

•

To flush only mix manifold, see Flush Mix Manifold procedure page 14.

Guidelines

Flush new systems if coating materials will be contaminated by 10W oil.

Flush system when any of the following situations occur.

Flushing will help prevent materials from clogging the line between hoppers and pump inlets.

• anytime sprayer will not be used for more than one week

• if materials used will settle

• if using thixotropic resins that require agitation

TI1949a

CD

air regulator

r_312359_313289_13

NOTE:

When flushing coating materials remove pump fluid filters, if installed, and soak in solvent to decrease cleaning time. Proceed with Step 2. If flushing a new system, leave filters in place.

2.

Move circulation return lines to separate fluid containers to pump remaining fluid out of system.

3.

Increase main pump air regulator (CD) pressure to

30 psi (21 kPa, 2.1 bar).

4.

Select .

NOTE:

.

When running pumps independently set to

. Press and or

as needed to clean.

NOTE:

If sprayer does not start with static pressure, increase air pressure by 10 psi (69 kPa, 0.7 bar) increments. To avoid splashing do not exceed 40 psi (28 kPa, 2.8 bar).

16 313289B

Flush

5.

Open recirculation valves (AC, AD) for respective pump dispense side. Run pumps until the A and B reservoirs are empty. Salvage the material in separate, clean containers.

9.

Close recirculation valves (AC, AD) and open mix manifold valves (AH, AJ). Dispense fresh solvent through mix manifold valves and out gun.

AD

AF

AC

AD

AC

AE

AH

AJ r_312359_313289_7

NOTE:

When priming or flushing the pumps, it is normal to get cavitation or pump runaway alarms. Clear the alarms

, and press again as necessary. These alarms prevent excessive pump speeds that can damage pump packings.

6.

Wipe the reservoirs clean, then add solvent to each.

Move circulation lines to waste containers.

7.

Repeat Step 4 to flush through each side until clean solvent exits recirculation hose.

8.

Stop and move recirculation hoses back to reservoirs. Continue recirculating until machine is thoroughly flushed.

10. Close mix manifold valves (AH, AJ).

11. Slowly open sampling valves (AE, AF) to flush solvent through until clean. Close sampling valves.

Press .

12. Follow Pressure Relief Procedure, page 12.

13. Remove pump fluid filters, if installed, and soak in solvent. Clean and replace filter cap. Clean filter o-rings and leave out to dry. Do not leave o-rings in solvent.

14. Close main air valve (E).

NOTE:

Always leave some type of fluid, such as solvent or oil, in the system to prevent scale build up. This build up can flake off later. Do not use water.

313289B 17

Shutdown Entire System

Shutdown Entire System

Follow this procedure before prolonged shutdown or before servicing equipment.

1.

Follow Pressure Relief Procedure, page 12. Place

gun over pail. Trigger gun; wait until pumps are down.

Cleaning Procedure

TI1953a

2.

Engage trigger lock, turn off air regulator, and close main air shutoff valve. Remove spray tip.

1.

Ensure all equipment is grounded. See Grounding, page 11.

2.

Turn off all heaters and allow equipment to cool.

3.

Flush mixed material. See Flush Mixed Material, page 14.

4.

Relieve pressure. See Pressure Relief Procedure, page 12.

5.

Shutdown sprayer and turn off all power. See Shut-

down Entire System, page 18.

6.

Ensure the area where the sprayer will be cleaned is well ventilated; and remove all ignition sources.

7.

Clean external surfaces using only a rag soaked in solvent that is compatible with the spray material and the surfaces being cleaned.

8.

Allow enough time for solvent to dry before using sprayer.

TI1949a

4)!

TI1948a

3.

Follow flushing procedure, see Flush on page 14.

4.



TI1949a

5.

For prolonged shutdown (one week or longer):

•

Follow flushing procedure, see Empty and

Flush Entire System (new sprayer or end of

job) on page 16.

• Cap fluid outlets to keep solvent in the lines.

• Fill pump A and B packing nuts with throat seal liquid (TSL).

18 313289B

Troubleshooting

Troubleshooting

NOTE:

If an error code displays, see Alarms on page 22.

NOTE:

The sprayer operates using air pressure. Many problems are caused by inadequate air supply. The inlet air pressure gauge cannot drop below 50 psi (0.35 MPa,

3.5 bar) while running.

Problem Cause Solution

Display not lit on system with alternator power supply.

No electric power.

Air valve not turned on.

Air supply pressure too low.

Air supply filters plugged. Inlet manifold filter (604) or air regulator (344) filter plugged.

Turbine air regulator (277) set too low.

Turn on main air valve to system.

Increase pressure to 30 psi (0.21 MPa,

2.1 bar) or greater.

Clean filter bowls; replace filter elements.

Page 29.

Alternator turbine failure.

Power supply not connected to main board.

Display board failure.

Display not lit on system with alternator power. Green light is present on FCM

(218) and USB (219), but no green light is present on back of display module (204).

Faulty CAN cable (268). Or CAN cable is disconnected.

Faulty display module.

Adjust to 18 +/- 1 psi (12.6 +/- 10 kPa,

1.26 +/- 0.07 bar).

Repair or replace turbine. Page 34.

Check power connections to main board.

See Electrical Schematics, starting on page 44.

Replace display board. Page 33.

Check cable and replace. See Alternator

Assembly, page 64.

Replace display module. See User Inter-

face/Control Box, page 30.

Reset main disconnect and breaker.

Display not lit on system with wall power supply. No green light present on back of display module (204).

No electric power. Disconnect “off” or breaker “open.”

No green lights present on display, FCM, or USB module.

Display not lit on system with wall power supply. Green light is present on back of display module (204).

No display power through CAN cable

(266). Green light in present on FCM

(218), but is not present on USB module

(219).

Green light is present on USB module

(219).

Display module failed.

Check for 24 Vdc on J1, pins 2 and 3, of

power supply. See Electrical Schemat-

ics, starting on page 44. If there is not 24

Vdc, replace with 15V747.

Check CAN cable. Replace if necessary.

See Wall Power Supply Assembly, page 65.

Check CAN cable (274). Replace if nec-

essary. See Wall Power Supply Assem-

bly, page 65.

Replace display module. See User Inter-

face/Control Box, page 30.

313289B 19

Troubleshooting


Pumps do not run.

Air pressure to pumps too low

Air pilot lines are obstructed

Solenoid valve stuck.

Increase pressure to 50 psi (0.35 MPa,

3.5 bar) or greater.

Check pilot lines for kinks or pinches.

Actuate solenoid manually, if it does not

operate, replace solenoid. Page 30.

Replace valve(s). Page 39.

Service or replace valve(s). Page 39.

See manual 311238.

Pump Test completes without error, but A or B component has more than 750cc of fluid in beaker.

Incorrect pumps were selected in System

Setup screens.

Air is trapped in fluid due to excessive agitation, circulation, and heat.

See Appendix A in manual 312359.

Repeat Pump Test with fresh fluid.

If the specific gravity of each fluid is known, check samples by weight (750cc x specific gravity equals weight in grams).

If weight is correct, extra volume in beaker is air.

Batch Test completes without error, but A or B component has more fluid in beaker than displayed on screen.

Sprayer does not start when start button is pressed.

See causes for previous pump test problem.

Faulty start switch or wire harness.

See solutions for previous pump test problem.

Faulty stop switch or wiring harness.

Check start switch and wiring harness continuity; switch is normally open circuit.

See Electrical Schematics, starting on page 44.

Check stop switch and wiring harness continuity; stop switch is normally closed

circuit. See Electrical Schematics, starting on page 44.

Fluid valves leaking.

Paint does not cure consistently.

Air pilot valve(s) to motor stuck.

Metering valve(s) not opening.

Air motor stalled.

Loose or worn packings.

Ratio not set correctly.

Tighten packing nut. If leak continues, replace packings.

Check that correct ratio is set and set by volume. See manual 312359.

Poor spray pattern.

Also, see “System runs erratically” below.

System runs erratically.

Material not mixing correctly.

Fluid A or B filters plugged.

Mixer or hoses partially plugged or too restrictive.

Test pump. Make sure mixer is clean; flush as needed. See manual 312359.

Position mixer after integrator hose.

Material not properly conditioned before it was added to sprayer.

Mix material thoroughly.

Not using enough integration hose.

Fluid pressure too low.

Add more integration hose.

Increase pump pressure.

Fluid temperature too low.

Spray tip dirty or worn.

Increase fluid temperature.

Relieve pressure. Clean or replace tip.

Follow gun manual instructions.

Clean filters. See pump manual.

Inspect parts for cured material. Clean or replace, or use larger hoses and mixer.

Air filter(s) clogged. Replace elements.

Air supply hoses undersized.

Air compressor undersized.

Air supply pressure tank undersized.

Inlet air pressure gauge drops below 50 psi (0.35 MPa, 3.5 bar) while spraying.

Clean. Replace element(s). See page 29.

Replace hoses with appropriate size.

Use larger air compressor.

Use larger pressure tank.

See solutions above for system runs erratically problem.

20 313289B

Troubleshooting


Air supply relief valve opens.

Turbine alternator makes high-pitched whining noise, or quits.

Display module cycles on and off.

Air regulator set too high.

Turbine bearings worn. (Setting turbine air regulator too high, wears bearings.)

Lower setting.

Replace turbine cartridge. See Alterna- tor Power Supply Control Compo-

nents, page 34.

Turbine is not supplying enough power to board.

Increase turbine regulator setting to

18 +/- 1 psi (12.6 +/- 10 kPa, 1.26 +/- 0.07 bar).

Check turbine and electrical control exhaust air for restrictions.

Flow rate too low.

Air supply hose is too small.

Replace turbine cartridge. See Alterna- tor Power Supply Control Compo-

nents, page 34.

Use 3/4 in. (minimum) ID hose. See

Technical Data, page 77.

Use larger CFM compressor.

Increase pressure.

Inadequate air supply.

Air pressure to pumps too low.

Fluid A or B filters plugged.

Spray tip too small.

Mixer or hoses partially plugged or too restrictive.

Receive ratio alarm after starting in spray mode while using remote mix manifold.

A and B hoses do not fill to correct pressure ratio simultaneously. Therefore, spray time increases in order to balance pressure. Ratio screen bar graph stays to one side until pressure balances.

Clean filters. See pump manual.

Relieve pressure. Install larger tip. Follow gun manual instructions.

Inspect parts for cured material. Clean or replace, or use larger hoses and mixer.

While in circulation mode, close circulation valves and increase pressure in hoses until correct spray pressure is achieved.

Select correct hose size to balance your volume ratio. See manual 312749.

Receive ratio alarm while using remote mix manifold after a significant change in pressure.

A and B hoses do not fill to correct pressure ratio simultaneously. Therefore, spray time increases in order to balance pressure. Ratio screen bar graph stays to one side until pressure balances.

While in circulation mode, close circulation valves and increase pressure in hoses until correct spray pressure is achieved.

Select correct hose size to balance your volume ratio. See manual 312749.

Change pressure slowly while spraying.

Erratic pressure at spray gun when using feed pumps.

Feed pressure is too high. Feed pressure at metering pump is too high on up stroke.

Use lowest feed pressure needed to maintain feed.

313289B 21

Alarms

Alarms

View Alarms

When an alarm occurs the alarm information screen automatically displays. It shows the current alarm code along with a bell icon. It also shows the alarm location with top and side views of the sprayer.

Diagnose Alarms

See Alarm Codes and Troubleshooting for causes

and solutions to each alarm code.

Clear Alarms

Press screen, press screen.

to clear alarms. From the alarm information

to return to the run (fluid control)

There are two levels of alarms: warnings and advisories.

A bell icon indicates an alarm. A solid bell icon with an exclamation point and three audible alerts indicate a warning. And an outlined hollow bell icon and a single audible alert indicate an advisory.

Advisories are notifications that require attention but not immediately. Warnings require immediate correction; therefore, sprayer operation automatically stops.

22 313289B

Alarms

Alarm Codes and Troubleshooting

Alarm

Code

R4B

R1B

REC

FHA

FHB

R2D

P4A

P4B

Alarm Problem When Active Cause Solution

General Performance Alarms

Ratio High B (Overdose B), system delivering too much B component.

Spray B Dosing valve not closing.

Perform Pump Test to test for leakage. See Pump and Metering test in manual 312359.

Loosen valve packing nut.

Check air signal at valve top

Repair valve or air solenoid.

See Replace Solenoid Mod-

ule, page 30.

No B restriction at mix manifold. Increase B Restriction by turning B restrictor stem clockwise.

See Adjust B Mix Manifold

Restriction in manual 312359.

Pump filter plugged on A side.

Clean filter. See manual

311762.

Ratio Low B (under dose B); system delivering not enough

B component.

Spray

System detected five R4B

(ratio high B) or five R1B

(ratio low B) alarms within five minutes. Sprayer shuts down for five minutes to resolve problem.

Spray

System detects pump movement (fluid flow) when valves are closed.

Spray

Inlet air dropping below 50 psi

(0.35 MPa, 3.5 bar) while spraying. B dosing valve not closing correctly.

Use alternate 30 mesh screen.

See manual 311762 for part number.

Check air filters. See Air Con-

trols, page 37.

Use larger air hose.

Use larger compressor.

Use smaller gun tips or less guns to reduce flow rate.

B dosing valve will not open.

B mix manifold valve closed.

Check for air signal to valve.

Open green mix manifold valve.

Pump filter plugged on B side.

Use alternate 30 mesh screen.

See manual 311762 for part number.

Clean B pump outlet filter. See manual 311762.

See R4B or R1B alarm causes. See R4B or R1B alarm solutions. Flush mixed material if necessary, and purge off-ratio mixed material in hose.

Recirculation valve or dosing valve open or leaking for more than 5 seconds.

Dosing sizes are not optimized.

Pressure high

Spray

Always

Dosing valve is operating near high or low timing limits.

Fluid pressure is above maximum.

Close or repair recirculation valve, and run Pump Test. See

Pump and Metering test in man-

ual 312359. See Mix Manifold


Adjust mix manifold B restrictor stem clockwise or counter clockwise as indicated by bar graph on ratio screen. See

Adjust B Mix Manifold Restriction in manual 312359.

Decrease main air regulator or feed pump pressure.

313289B 23

Alarms

Alarm

Code

DAA

DAB

DDA

DDB

P1A

P1B

P4R

P5R

DFA

DFB

DGA

DGB

DEA

DEB

DJA

DJB


Pump runaway, above 60 cpm for 10 sec.

Pump cavitation; dives more than 3/4 of stroke.

Pressure low.

Pressure high.

Pressure high.

Always

Always

Spray, Pump

Test, Leak Test

Recirculation

Recirculation

No material in pump or lines; no fluid restriction.

No fluid or valve closed.

Refill material in tank or hoses; install fluid tip.

Refill supply and open inlet valve.

Material is too cold or thick.

Pump inlet check valve not closing.

Pressure is above maximum advisory limit of 3000 psi (21

MPa, 210 bar).

Pressure is above maximum warning limit of 5200 psi (35.9

MPa, 359 bar).

Increase material temperature to reduce viscosity. (See Heat

Fluid section in manual

312359.) Shear material with agitation to reduce viscosity.

Clear debris from check valve.

Or replace ball, seat, and seal.

See Pump Assembly, page

41.

Check feed pump (if used).

Feed pump not providing material.

Inlet strainer plugged (if used).

Check and clean strainer. See

Pump Assembly, page 41.

Fluid pressure is below 1000 psi (7 MPa, 70 bar).

Increase main air regulator.

Decrease pump air regulator pressure.

Decrease pump air regulator pressure.

Pump did not stall against fluid pressure on up stroke only.

Pump Test (Daily Check Recommended)

Pump Test

Pump did not stall against fluid pressure on down stroke only.

Pump does not move in 10 minutes.

Pump Test

Park or Pump

Test

Pump piston check valve, piston packings, or dosing valve are not holding fluid pressure.

Pump inlet check or dose valve is fouled, or damaged.

Recirculation valves were not opened to allow flow.

Flush pump. See Flush, page

14. Recheck. Remove, clean,

and repair lower. See Pump


Remove inlet housing & clean

and inspect. See Pump


Open recirculation valves.

Pump motor linear sensor has no signal.

General System Component Alarms

Always No linear sensor signal from motor.

Swap A and B sensors.

Replace sensor if problem follows sensor.

PJA

PJB

Pump motor linear sensor is out of range.

Pump linear sensor is out of range.

Always

Always

Linear sensor plugged in while power is on.

Power sprayer off and back on.

Do not plug in linear sensor while power is on.

Linear sensor is beyond range.

Replace sensor or sensor magnet.

Linear sensor signal is beyond range.

Replace sensor or sensor mag-

net. See Pump Assembly, page 41.

Sprayer is not properly grounded.

See Grounding, page 11.

24 313289B

Alarms

Alarm

Code

DKA

DKB

P6A

P6B

V1M

P1M

N6C

MAA

MAB

MEA

MEB

MG0

P5A

P5B


Pump motor reed switch failure; missing signals from one or both switches.

Always

Pressure sensor failure; no signal.

Voltage low control

Low air supply warning; voltage drops below 10 Vdc when pumps move. (Turbine power supplies only).

Display has no signal.

Maintain pump

Maintain dosing valve

Maintain air filter

Always

Always

Always

Always

Bad motor cable connections, or bad reed switch.

Reed switch cable is plugged in while power is on.

Swap A and B motor cables.

Replace cable if problem persists. Otherwise replace reed sensor assembly.

Power sprayer off and back on.

Do not plug in reed switch cable while power is on.

Pressure sensor or cable is bad on the A or B side.

Replace sensor and cable

assembly. See Pump Assem-

bly, page 41.

Voltage dropping below 10 Vdc from power supply.

Change air filter in control filter

regulator. See Replace Air Fil-

ter Element, page 29.

Check the pressure setting is

18 psi (0.12 MPa, 1.24 bar) on turbine air regulator.

Turbine not spinning with air on. Replace air turbine cartridge.

See Alternator Power Supply

Control Components, page

34.

Filter plugged and/or air motors are using available air and not leaving enough for turbine control voltage.

No display communication signal.

Change large air filter and con-

trol air filter. See Replace Air

Filter Element, page 29. Use a

larger air supply. Use smaller spray tips.

Check cable connections.

Replace display.

Optional User-Settable Maintenance Warnings

Always, if enabled Pump usage exceeds user-set limit. Maintenance due.

Always, if enabled Dosing valve usage exceeds user-set limit. Maintenance due.

Always, if enabled Air filter exceeds user-set limit.

Maintenance due.

Service pump. See Pump


Service dosing valve. See Dos-

ing Valve Assembly, page 39.

Pressure exceeded warning limits

Always, if enabled Pressure exceeded high or low warning limits for more than 15 seconds.

Service main air filter and con-

trol filter regulator. See Replace

Air Filter Element, page 29.

Adjust pump pressure regulator, change tips, or adjust target set point.

313289B 25

Alarms

Alarm

Code

T5A

T5B

P2A

P2B

T2A

T2B

N4D


Temperature exceeded warning limits

Optional User-Settable Spray Limits

Always, if enabled Fluid temperature exceeded high or low warning limits for more than four minutes.

If fluid temperature is too low, return to circulation mode to increase fluid temperature.

Adjust heater set point if needed.See Heat Fluid section in manual 312359.

If fluid temperature is too high, lower heater set point, and return circulation mode to cool.

See Heat Fluid section in manual 312359.

Adjust temperature target setpoint. See Heat Fluid section in manual 312359.

Same as P5A or P5B.

Pressure exceeded advisory limits

Temperature exceeded temperature limits

Pot life timer expired. Mixed fluid will cure in hoses, mixer, and gun.

Always, if enabled Pressure exceeded high or low advisory limits for more than 15 seconds.

Always, if enabled Fluid temperature exceeded high or low limits for more than four minutes.

Spray Have not sprayed enough volume to keep fresh mixed fluid in the integration hose, mixer, whip hose, and spray gun.

Same as T5A or T5B.

Spray fluid, or flush. Resets when you leave spray mode.

See manual 312359. See

Flush, page 14.

26 313289B

Alarms

Possible Alarms by Mode

The following table outlines the alarms that you may receive while operating the system. The alarms are categorized according to each mode.

Mode Control Logic Alarms

Spray

Park

Circulation

Pump Test

Dosing valves close for startup test; green light blinks.

If fluid pressure is under 1000 psi (7 MPa, 70 bar), STOP.

If pumps move (indicating internal leakage), STOP.

If fluid pressure is more than 103% of allowed maximum, air motor shuts off.

If is pressure more than 110% of allowed maximum, STOP.

Dosing valve A opens, and dosing valve B cycles to maintain ratio.

Blue lights when dosing valves are operating.

If there is not enough B component to hold ratio, dosing valve A closes momentarily.

If A or B component is more than 5% off ratio setpoint, STOP.

Both dosing valves open; A and B blue lights turn on.

User opens circulation valves or sprays gun. When pump reaches bottom stroke the blue light turns off.

If park does not complete in 10 minutes, turn off air to both motors.

A and/or B dosing valves open and motor air turns on.

If fluid pressure exceeds 3000 psi (21.0 MPa, 210 bar), receive yellow light advisory.

If fluid pressure exceeds 5600 psi (39.2 MPa, 392 bar), STOP.

If no movement in 10 minutes, turn off air to both motors.

Both dosing valves close; green light blinks.

If fluid pressure is under 1000 psi (7.0 MPa, 70 bar), STOP.

If pumps move (indicating leakage) STOP.

Turn on A blue light, open A dosing valve, user opens sampling valve.

Close A dosing valve on upstroke; check for no movement.

Close A dose valve on down stroke; check for no movement.

If pump moves on both up and down strokes.

Open A dose valve and dispense total of 750 ml material, close valve, turn off blue light.

Repeat for B side.

If both pumps pass pump test, display shows two beakers of 750ml each.

Batch Dispense Test User selects total volume desired.

Open A dosing valve, turn on blue light, user opens sampling valve, turn off blue light when complete.

Valve Test

Open B dosing valve, turn on blue light, user opens sampling valve, turn off blue light when complete.

Display shows volume of A and B components at end of batch dispense test.

If fluid pressure is not 1000 psi (7 MPa, 70 bar), STOP.

Check for no movement of pumps (stall within 10 seconds).

--

P1A

FHA, F4A, F4B, FHB

None

P4B

--

--

R5D

R4A, R4B, R1A, R4B

--

--

DE--

--

P4A, P4B

P4A, P4B

DEA, DEB

--

P1A, P1B

F4A, F4B

--

DFA

DGA

DHA

--

DFB, DGB, DHB

--

--

--

--

--

P1A

F4A, F4B

313289B 27

Alarms

Alarm Code Key

Use the following table as a quick guide to determine alarm codes.

What Alert

T

V

D

F

N

P

R

Flow

Time

Pressure

Ratio

Temperature

Voltage

Pump

4

5

1

2

6

Low

Deviation

High

Limit warning

Sensor or connection failure

M Maintenance due

J

K

G

H

E

F

A

D

A

E

G

Pump runaway

Pump diving/cavitation

Pump time-out

Pump failed to stall up

Pump failed to stall down

Pump failed to stall

Linear sensor failure

Directional switch failure

Pump

Dosing valve

Filter

A

B

C

D

M

R

Where

Material A

Material B

Controller

Dosing/Pot life

Power or Air supply

Recirculation

28 313289B

Repair

Repair

4.

Remove and replace element.

344

Follow Shutdown Entire System procedure, page 18, if

service time may exceed pot life time, before servicing fluid components, and before transporting sprayer to a service area.

Filter Bowl and Element

Replace Air Filter Element

There are two air filters on the system: the inlet air regulator filter on the air controls and the main air inlet manifold filter. Check filters weekly and replace element as needed.

Removing a pressurized air filter bowl could cause serious injury. Do not service air filter until air line is depressurized.

r_312359_313289_15

5.

Screw filter bowl on securely.

Main Air Inlet Manifold Filter

2.

Unscrew filter bowl from main air inlet manifold (6).

3.

Remove and replace filter element (604a). See Air

Inlet Manifold (255762) Parts, page 69.

Both Filters

1.

Close main air shutoff valve on air supply line and on unit. Depressurize air line.

Control Air Regulator Filter

2.

Remove front and rear shrouds (12, 13). Remove four nuts (14) and then shrouds.

12

604a

13

14

Filter Bowl r_312359_313289_b_6

4.

Reassemble filter bowl.

5.

Replace front and rear shrouds (12, 13) using four nuts (14).

3.

Unscrew filter bowl from inlet air regulator (344).

313289B 29

Repair

User Interface/Control Box

NOTE:

This section covers all components included in the wall power supply control box option and the instrinsically safe pneumatic power supply control box option.

Remove Shroud

1.

Close main air shutoff valve on air supply line and on system.

2.

Remove shrouds (12, 13) covering control box.

Remove four nuts (14) and front shroud (12) first.

14

5.

Disconnect air tubing from solenoid manifold block

(209).

NOTE:

If your sprayer is an intrinsically safe model, you will need to remove the alternator air regulator from the

solenoid module. See Replace Alternator Regulator, page 35, for removal instructions.

6.

Remove two screws (210).

210

13

209

12

14 r_312359_313289_17

Replace Solenoid Module

Follow this procedure to replace a single solenoid

1.

Remove shroud. See Remove Shroud.

2.

Disconnect power.

3.

Remove four nuts (4); leave two nuts on left side of panel tight. Open front panel of control box (11).

11

7.

Remove and replace solenoid (209).

8.

Reassemble screws (210) and solenoid cable connectors (242).

NOTE:

From left to right, solenoid functions are as follows:

• Dosing valve A (DVA) (normally open)

• Dosing valve B (DVB) (normally open)

• Pump A (PA) (normally closed)

• Pump B (PA) (normally closed)

DVA

4

DVB

PA

PB r_xm1a00_312359_313289_9_3 r_312359_313289_18

4.

Disconnect solenoid cable connectors (242) from solenoids.

30 313289B

Repair

Replace USB Module

1.


2.

Disconnect power.

3.


4.

Disconnect CAN cables and USB cable from USB module (219).

5.

Remove two mounting screws from USB module and remove module from base.

5.

Loosen four mounting screws (235).

r_312359_313289_26

218

235

235

219

6.

Follow steps in reverse order to install new USB module.

Replace Fluid Control Module (FCM)

NOTE:

The USB module does not need to be removed prior to replacing the FCM.

1.


2.

Disconnect power.

3.


4.

Remove all cables from FCM (218). Take note of cable locations.

6.

Slide FCM up and out of keyhole slots.

7.

Follow steps in reverse order to install new FCM.

Replace Alarm

1.


2.

Disconnect power.

3.


4.

Disconnect alarm wires from alarm (217).

5.

Unscrew alarm (217) and replace.

217

6.

Screw in new alarm. Reconnect alarm wires. Refer

to Electrical Schematics, page 44.

7.

Reassemble air control front shroud (12).

313289B 31

Repair

Display

Upgrade Software

Do not upgrade software when an explosive gas atmosphere may be present.

8.

Turn power off.

9.

Remove token (T).

10. Reassemble access cover (204e) and screws

(204f).

Replace Display Battery

NOTICE

To avoid damaging circuit board, wear a grounding strap.

1.


2.

Disconnect power.

3.


4.

Remove four screws (204f) and then access cover

(204e).

Do not replace battery when an explosive gas atmosphere may be present.

NOTICE


1.

Perform steps 1-4 under Upgrade Software section, page 32.

2.

Use a flat head screwdriver to pry out old battery.

Remove Old Battery

204f

Battery

L

204e

Insert New Battery

Connector

Tabs r_xm1a00_312359_313289_9_8a

T r_xm1a00_312359_313289_2a

5.

Insert and press token (T) firmly into slot.

NOTE:

There is no preferred orientation of token.

6.

Turn power on.

7.

The red indicator light (L) will flash until new software is completely loaded. After the software load is complete the green light will constantly flash.

3.

Replace with new battery. Ensure battery fits under connector tabs before snapping other end in place.

NOTE:

Use only Panasonic CR2032 batteries for replacement.

4.

Reassemble access cover (204e) and screws

(204f).

32 313289B

Repair

Replace Display

NOTE: Order kit 257484 for replacement.

NOTICE


7.

Remove front display panel (204d) and gasket

(204g).

Display Cable

204d

239

1.


2.

Disconnect power.

3.


4.

Disconnect CAN cable from display module.

5.

Remove four screws (204b) from rear display panel

(204c) while holding front display panel (204d) in place.

NOTE:

To ease removal process use clear tape to hold front display panel (204d) in place.

9

2

_

5 a

_

3

3

0

0

1 x r_

6.

Remove rear display panel (204c) and disconnect display cable and key switch cable (239) from circuit board.

204c

204d

204b

204g

204c

204b

8.

Discard old display assembly.

9.

Place new front display panel (204d) and gasket

(204g) on front panel of control box (11).

NOTE:

To ease installation process use clear tape to hold front display panel in place.

10. Carefully connect display cables and key switch cable to new circuit board.

11. Install new rear display panel (204c) and secure with four screws (204b). Ensure key switch cable protrudes from opening in top of display module.

12. Install access cover and screws. Apply warning label to access cover.

13. Reconnect CAN cable to display module.

14. Reconnect power.

15. Replace shroud.

16. Press . Configure system settings as they were set on old display. See XM Plural-Component

Operation manual 312359 for instructions.

Replace Front Panel

See Replace Display, page 33, for instructions

313289B 33

Repair

Wall Power Supply Control Components

Replace Power Supply Module

1.


2.

Disconnect main power.

3.


4.

Disconnect incoming power cable connections to power supply module and ground lead (260) from control box.

5.

Disconnect power supply cable (272) from FCM

(218).

6.

Remove four screws (273) holding power supply module (270) bracket in place.

3.


4.

Disconnect output power cable connections from alternator module and ground lead from control box.

5.

Disconnect power supply cables from FCM, USB, and display.

Air Reg.

FCM

Display

USB Exhaust

272

270

6.

Disconnect air regulator air line and exhaust air line.

7.

Remove four screws (263) from mounting to remove alternator from control box.

r_256991_313293_7

273 r_256991_313293_3a-1

260

7.

Remove and replace power supply module (270).

8.

Follow steps in reverse order to install new power supply module.

260

263

Alternator Power Supply Control

Components

Alternator Module Repair

Alternator Repair Kit 257147 is available to replace turbine bearings.

1.


2.


34 313289B

Repair

8.

Remove seven screws (708) to separate alternator housings.

9.

Replace turbine (704) if necessary. Lightly lubricate turbine o-ring to ease alternator housing reassembly.

4.

Disconnect supply air line from alternator assembly

(265).

265

708

708

704

209

277

Supply Air Line

705

702

703 r_xm1a00_312359_313289_9_4a-1

5.

Loosen air regulator swivel fitting (276) and remove from solenoid module (209).

209

10. Replace gasket (702) and/or circuit board assembly

(705) if damaged.

11. Follow steps in reverse order to reassemble alternator regulator assembly and to reconnect power

cables and air lines. Refer to Electrical Schemat-

ics, page 44.

NOTE:

Avoid causing a kink in the flexible circuit board when you reconnect the circuit board assembly (705).

Replace Alternator Regulator

1.

Remove shroud. See Remove Shroud, page 30

2.


3.


276

6.

Repair or replace alternator regulator parts as nec-

essary. See Alternator Assembly, page 64, for

repair parts. Replace air regulator swivel fitting

(276).

7.

Set regulator to 18 +/- 1 psi (12.6 +/- 10 kPa, 1.26 +/-

0.07 bar).

313289B 35

Repair

36 313289B

Repair

Air Controls

Remove Air Control Assembly

1.

Remove shroud. See Remove Shroud, page 30.

2.

Disconnect air motor air lines and system air line.

3.

Remove four nuts (7) from front of air control bracket

(319).

4.

Pull out assembly.

5.

Follow steps in reverse order to reinstall air control assembly.

Replace Solvent Pump Ball Valve

1.


2.


3.


(319).

4.

Pull out assembly.

5.

Remove two nuts (330) from front of air control bracket (319).

6.

Disconnect air line (332) running to ball valve assembly (326).

7.

Replace with new ball valve assembly. See Air Con-

trols Module (255761) Parts, page 66.

8.

Follow steps in reverse order to reassemble.

Replace Solvent Air Regulator

1.


2.


3.


(319).

4.

Pull out assembly.

5.

Remove regulator nut (331), and disconnect air lines (332, 333) running to regulator (325).

6.

Remove regulator assembly and replace with new.

See Air Controls Module (255761) Parts, page 66.

7.


Replace System Air Regulator

1.


2.


3.


(319).

4.

Pull out assembly.

5.

Remove regulator nut (340) and disconnect system air line.

6.

Remove screws from quick clamps and open clamps (342b, 342c) at hinge.

7.

Remove regulator assembly (345) and replace with

new. See Air Controls Module (255761) Parts, page 66.

8.


Replace Solenoid Inlet Air Regulator

1.


2.


3.


(319).

4.

Pull out assembly.

5.

Disconnect air line.

6.

Remove gauge from block (343).

7.

Remove screws from quick clamps (342a, 342b) holding air regulator assembly (344) in place.

8.

Open clamps (342a, 342b) at hinge and pull apart from block (343).

9.

Remove regulator assembly (344) and replace with

new. See Air Controls Module (255761) Parts, page 66.

10. Follow steps in reverse order to reassemble.

313289B 37

Repair

342a

342b

319

Gauge

326

343

7

330

340

331

Gauge

332

325

344

345

342c

332

333

342d r_xm1a00_312359_313289_9_9

38 313289B

Repair

Fluid Control Assembly

Dosing Valve Assembly

1.


2.

Disconnect all fluid lines from dosing valve assembly (8).

3.

Remove three bolts (16) on back of each dosing valve (501) from bracket.

4.

Unscrew dosing valve housing seats from adapters on mix manifold.

6.

Remove dosing valves. See manual 313342 for dosing valve service and repair instructions.

7.

Follow steps in reverse order to reassemble dosing valve assembly.

Mix Manifold Assembly

1.


2.

Disconnect fluid line and solvent lines from mix manifold assembly.

3.

Loosen four bolts securing mix manifold (508) to bracket.

508

Bracket

Bolts

Bolts

Housing

Seat

Adapter

5.

Disconnect RTD (506) from cord grip. Disconnect pressure sensor (507) and fluid line adapter from each dosing valve (501).

501

Fluid Line

Adapter

.

Bracket

16

506

4.

Unscrew dosing valve housing seats from adapters on mix manifold.

5.

Remove four bolts securing mix manifold (508) to bracket.

6.

Remove mix manifold assembly (508) from bracket.

See manual 312749 for mix manifold service and repair instructions.

7.

Follow steps in reverse order to reassemble mix manifold assembly.

r_312359_313289_41

313289B 39

Repair

Sensors

Replace Fluid Pressure Sensor

1.


2.

Relieve fluid pressure. See Pressure Relief Proce-

dure, page 12.

3.

Open control box cover. See User Interface/Con-

trol Box, page 30.

4.

Disconnect pressure sensor (507) from FCM (218).

5.

Disconnect fluid pressure sensor (507) from dosing valve (501).

Temperature (RTD) Sensor

1.


2.

Relieve fluid pressure. See Pressure Relief Proce-

dure, page 12.

3.

Open control box cover. See User Interface/Con-

trol Box, page 30.

4.

Disconnect temperature sensors (506) from FCM

(218).

507

501

506

218 r_xm1a00_312359_313289_15a

506 Cord Grip

507 r__312359_313289_30

6.

Replace with new fluid pressure sensor, and reconnect pressure sensor to FCM.

5.

Remove RTD (506) cable from cord grip.

6.

Replace with new temperature (RTD) sensor.

7.

Reassemble RTD cable (506) and cord grip.

8.

Connect temperature (RTD) sensor to FCM.

9.

Close control box cover.

40 313289B

Repair

5.

Remove pump assembly by lift ring on air motor.

Pump Assembly

Do not lift pump assembly by the lift ring when the total weight of the pump assembly exceeds 550 lb (250 kg).

Prior to servicing the pump assembly you must first remove either the entire pump assembly or the displacement pump and air motor individually.

Remove Pump Assembly

1.


2.

Close ball valve on hopper outlet assembly.

3.

Disconnect displacement pump from fluid inlet assembly.

• 50:1 Pump: disconnect reducer bushing fitting from swivel fitting on fluid inlet assembly.

• 70:1 Pump: disconnect reducing swivel from fluid inlet assembly.

Reducing

Swivel

Swivel Fitting

6.

Refer to Xtreme Displacement Pump manual

311762 to service or repair the displacement pump.

Refer to NXT Air Motor manual 311238 to service or repair the air motor.

7.

Follow steps in reverse order to reinstall pump assembly.

Remove Displacement Pump

Follow these instructions for removing only the displacement pump; the air motor will remain installed.

1.


2.

Disconnect displacement pump from fluid inlet

assembly. See steps 2 and 3 under Remove Pump


3.

Remove clip (133), and slide coupling cover (134) up to remove coupling (132).

134

Ball Valve

Reducer

Bushing

132 r_xm1a00_312359_313289_5a-2

133

NOTE:

Refer to the Double Wall Hopper manual 312747 to service or repair the fluid inlet assembly.

ti8264a

4.

Disconnect air motor.

a.

Disconnect sensor cable, air line, and ground wire from air motor.

b.

Remove mounting screws (4) and washers (3) holding air motor (2) to mounting bracket. See

illustration in Remove Air Motor section.

313289B 41

Repair

4.

Use a wrench to hold the tie rod flats to keep the rods from turning. Unscrew the nuts (129) from the tie rods (128) and carefully remove the displacement pump (66 or 67).

66 or 67

128

Remove Air Motor

1.


2.

Disconnect displacement pump from air motor. See

steps 2 and 3 under Remove Displacement Pump, page 41.

3.

Disconnect sensor cable, air line, and ground wire from air motor.

4.

Remove mounting screws (4) and washers (3) holding air motor (2) to mounting bracket.

129 ti8301a

5.

Refer to the Xtreme Displacement Pump manual

311762 to service or repair the displacement pump.

6.

Follow steps in reverse order to reinstall displacement pump.

2

Bracket

3

4 r__312359_313289_32

5.

Refer to NXT Air Motor manual 311238 to service or repair the air motor.

6.

Follow steps in reverse order to reinstall air motor.

42 313289B

Repair

Solvent Pump

1.


2.

Disconnect fluid line (140) and air lines (107, 126) from solvent pump.

3.

Remove four screws (106) that attach solvent pump

(103) to bracket (138) and remove solvent pump.

103

106

126

138

107

Fluid Heaters

NOTE:

Wiring for explosion-proof heaters (245863) is not provided. See Viscon HP heater manual 309524 for wiring, repair, and parts information for explosion-proof heaters.

Service and Repair

1.


2.

Disconnect fluid lines and electrical wiring from fluid heater.

3.

Refer to Viscon HP heater manual 309524 to service or repair heater.

4.

Reconnect fluid lines and electrical wiring.

Replace

1.

Follow steps 1 through 2 above.

2.

Loosen four mounting screws (X), lock washers (Y), and plain washers (127) on back of heater (90).

Slide heater up and remove from mounting plate.

140

106

4.

Refer to Merkur Pump Assembly manual 312794 to service or repair solvent pump.

5.

Follow steps in reverse order to reinstall solvent pump.

127

X

Y

90

Mounting Plate r__312359_313289_34

3.

Replace heater. Follow steps in reverse order to install new heater.

313289B 43

Electrical Schematics

Electrical Schematics

Simplified Electrical Schematic, XM Sprayer with Alternator

XM PLURAL COMPONENT SPRAYER WITH ALTERNATOR

Control

Cable, CAN

(15V783)

Display Module,

Rear (288997)

Front (255727)

1.5FCM

(Min)

Alternator

Module

(255728)

Cable, CAN

(15V782)

Cable, CAN

(15V778)

USB MODULE

Base (289899)

Top (289900)

Fluid

Control

Module

(255920)

44

Air Motor A Side

Junction Box

(287733)

Linear Sensor

(256893)

Reed Switch

(119700)

Pressure

Transducer

A Side

(15M669)

Temp

Sensor

RTD

A Side

(15R347)

Pressure

Transducer

B Side

(15M669)

Temp

Sensor

RTD

B Side

(15R347)

Air Motor B Side

Junction Box

(287733)

Linear Sensor

(256893)

Reed Switch

(119700)

313289B

Simplified Pneumatic Schematic, XM Sprayer with Alternator


313289B 45


Detailed Electrical Schematic, XM Sprayer with Alternator (page 1)

46

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

CAN_L +V_CAN

V CAN V CAN

CHASSIS GND CHASSIS GND V CAN R

BIT3 BIT2 GND SCK S0 S1 V CAN V CAN V CAN

CAN L CAN H

BIT0 BIT1

OKEN LOFO /HOLD /CS

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

LED_RED NO

CAN_L +V_CAN

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9

SIG CO

1 2 3 4

1 2 3 4 5

CAN_L +V_CAN

1 2 3 4 5

CAN_L +V_CAN

CAN_L +V_CAN CAN_L +V_CAN CAN_L +V_CAN

1 2 3 4 5 1 2 3 4 5 1 2 3 4 5

NOTE: NC indicates the wire is not connected.

313289B


Detailed Electrical Schematic, XM Sprayer with Alternator (page 2)

DOSE A

MOTOR A

Switch,

Start NO

(121618)

Buzzer

(122000)

Manifold

Pressure

Transducer

(15M669)

CAN_L

+V_CAN

V_CAN_RTN

CAN_H

SHLD

Harness, Stop

(15M976)

+V_CAN

NC

NC

+SIG(START)

+SIG(ALARM)

Harness,Solenoid

(15M977)

NC

+SIG

COM

+SIG

NC

+EXE(5VDC)

-PRESSURE

-EXE(COM)

+PRESSURE

SHLD

J12

3

4

1

2

5

J2

3

4

1

2

5

J4

3

4

1

2

5

J8

3

4

1

2

5

Air Motor

Junction

Box

(287733)

Linear

Sensor

(256893)

Reed

Switch

(119700)

Temp

Sensor

RTD

(15R347)

Harness, Air Motor

(15R345)

LINEAR_SENS

NC

REED_TOPCHGOVR

REED_BTMCHGOVR

COM(REED)

+5V(LINEAR_SENS)

COM(LINEAR_SENS)

SHLD

+EXCITE

SHLD

CONDUCTOR

SENSE

UNUSED

UNUSED

UNUSED

UNUSED

J25

3

4

1

2

J25

3

4

1

2

J14

7

8

5

6

3

4

1

2

FLUID

CONTROL

MODULE

(255920)

7

8

5

6

3

4

1

2

J15

3

4

1

2

5

J7

3

4

1

2

5

J5

3

4

1

2

5

J13

3

4

1

2

5

J3

CAN_L

+V_CAN

V_CAN_RTN

CAN_H

SHLD

Harness, Stop

(15M976)

+V_CAN

NC

NC

+SIG(STOP)

NC

Harness,Solenoid

(15M977)

NC

+SIG

COM

+SIG

NC

+EXE(5VDC)

-PRESSURE

-EXE(COM)

+PRESSURE

SHLD

Switch,

Stop NC

(121619)

Manifold

Pressure

Transducer

(15M669)

DOSE B

MOTOR B

Harness, Air Motor

(15R345)

LINEAR_SENS

NC

REED_TOPCHGOVR

REED_BTMCHGOVR

COM(REED)

+5V(LINEAR_SENS)

COM(LINEAR_SENS)

SHLD

Air Motor

Junction

Box

(287733)

Linear

Sensor

(256893)

Reed

Switch

(119700)

3

4

1

2

J11

3

4

1

2

J11

+EXCITE

SHLD

CONDUCTOR

SENSE

UNUSED

UNUSED

UNUSED

UNUSED

Temp

Sensor

RTD

(15R347)


313289B 47


Simplified Electrical Schematic, XM Sprayer with Wall Power

XM PLURAL COMPONENT SPRAYER WITH WALL POWER

Control

Display Module,

Rear (288997)

Front (255727)

Power

Filter

(115306)

Power

Supply

(15V747)

Cable, CAN

USB MODULE

Base (289899)

Top (289900)

Fluid

Control

Module

(255920)

Air Motor A Side

Junction Box

(287733)

Linear Sensor

(256893)

Reed Switch

(119700)

Pressure

Transducer

A Side

(15M669)

Temp

Sensor

RTD

A Side

(15R347)

48

Pressure

Transducer

B Side

(15M669)

Temp

Sensor

RTD

B Side

(15R347)

Air Motor B Side

Junction Box

(287733)

Linear Sensor

(256893)

Reed Switch

(119700)

313289B

Simplified Pneumatic Schematic, XM Sprayer with Wall Power


313289B 49


Detailed Electrical Schematic, XM Sprayer with Wall Power (page 1)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

CAN_L +V_CAN V CAN V CAN

CHASSIS GND CHASSIS GND V CAN R

BIT3 BIT2 GND SCK S0 S1 V CAN V CAN V CAN

CAN L CAN H

BIT0 BIT1 OKEN LOFO /HOLD /CS

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

CAN_L +V_CAN

LED_RED NO

SIG CO

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10

11 12 13 14

1 2 3 4 5 6 7 8 9

1 2 3 4

1 2 3 4 5

CAN_L +V_CAN

1 2 3 4 5

CAN_L +V_CAN

1 2 3 4 5

50

NOTE: NC indicates the wire is not connected. See manual 312359 for power connection instructions.

313289B

Detailed Electrical Schematic, XM Sprayer with Wall Power (page 2)


313289B

DOSE A

MO T OR A

Switch,

Start NO

( 1 2 1 6 1 8)

Bu zz er

( 1 22000)

Mani f o l d

Pressure

T ransducer

( 1 5M669)

Air Motor

Junction

Box

(287733)

Linear

Sensor

(256893)

Reed

Switch

( 11 9700)

T emp

Sensor

R T D

( 1 5R347)

Harness, Air Motor

( 1 5R345)

LINEAR _ SENS

NC

REED _T OPCHGOVR

REED _ B T MCHGOVR

COM(REED)

+ 5V(LINEAR _ SENS)

COM(LINEAR _ SENS)

SHLD

+ E X CI

SHLD

CONDUC

T

SENSE

T

E

OR

UNUSED

UNUSED

UNUSED

UNUSED

CAN _ L

+ V _ CAN

V _ CAN _ R T N

CAN _ H

SHLD

Harness, Stop

( 1 5M976)

+ V _ CAN

NC

NC

+ SIG(S T AR T )

+ SIG(ALARM)

Harness,So l enoid

( 1 5M977)

NC

+ SIG

COM

+ SIG

NC

+

-PRESSURE

-E

+

E X

X

E(5VDC)

E(COM)

PRESSURE

SHLD

J8

J4

J 1 2

3

4

1

2

5

J2

3

4

1

2

5

3

4

1

2

5

3

4

1

2

5

J 1 4

7

8

6

5

3

4

1

2

J25

3

4

1

2

J25

3

4

1

2

FLUID

CON T ROL

MODULE

(255920)


3

4

1

2

5

J7

3

4

1

2

5

J5

3

4

1

2

5

J 1 3

3

4

1

2

5

J3

CAN _ L

+ V _ CAN

V _ CAN _ R T N

CAN _ H

SHLD

Harness, Stop

( 1 5M976)

+ V _ CAN

NC

NC

+ SIG(S T OP)

NC

Harness,So l enoid

( 1 5M977)

NC

+ SIG

COM

+ SIG

NC

+

+

E X E(5VDC)

-PRESSURE

-E X E(COM)

PRESSURE

SHLD

Switch,

Stop NC

( 1 2 1 6 1 9)

Mani f o l d

Pressure

T ransducer

( 1 5M669)

7

8

5

6

3

4

1

2

J 1 5

3

4

1

2

J 11

3

4

1

2

J 11

Harness, Air Motor

( 1 5R345)

LINEAR _ SENS

NC

REED _T OPCHGOVR

REED _ B T MCHGOVR

COM(REED)

+ 5V(LINEAR _ SENS)

COM(LINEAR _ SENS)

SHLD

+ E X CI

CONDUC

T

SHLD

SENSE

T

E

UNUSED

UNUSED

UNUSED

UNUSED

OR

T emp

Sensor

R T D

( 1 5R347)

Air Motor

Junction

Box

(287733)

Linear

Sensor

(256893)

Reed

Switch

( 11 9700)

DOSE B

MO T OR B

51

Junction Box Wiring Schematics

Junction Box Wiring Schematics

Fluid Heaters

NOTE: See manual 312359 for power connection instructions.

52

TERS FLUID HEA

313289B

Hopper Heaters

Junction Box Wiring Schematics

313289B

HOPPER HEATERS

53

Parts

Parts

XM Plural-Component Sprayers

1

Do not use swivel union end on mixer inlet. Use female pipe thread.

XM_B_ _ Models

92

91

7

15 (attaches to 317)

94

95

8

XM1, XM2,

XM3, XM4

Models

31

126

58

5

107 (attaches to 325)

102

56

55

16

55

53

54

60, 61

58 59 1 65 62

63

64

1

28

100

101

54 313289B

Parts


14

17, 19, 20

7

18

108

15

32

12

14

11

13 2a

2

4

3

104

128

107

144

143

103

105

138

134

131

133

132

129

142

126

106

66 or 67

140

6

7

115

53

53

116

117, 118, 119

53

54

XM_B_ _ and XM_E_ _

Models

313289B

90, 127

139

141

76

86

88

85 84

83

80

81

82

52

76

87

XM5, XM6,

XM7, XM8

Models

109

80, 125, or 146

93

16

89

55

Parts


22

113

114

120

121

122

135

21 27

23

30

29

24

51

24

53

69

70

68

137

38

33

34

23

96

58

115

56 313289B

Parts

Common Parts

Ref.

Part Description Qty.

7

8

1

2

FRAME

257055 MOTOR, 6500, de-icing; see manual 311238

2a 256893 HOUSING, assy., linear sensor;

3

4

5 see manual 311328

2b  NXT102 CONTROL, assy, de-ice

100133 WASHER, lock

100101 SCREW, cap, hex hd

255761 AIR CONTROLS, module, upper;

6

see Air Controls Module

(255761) Parts, page 66

255762 MANIFOLD, inlet, air distribution;

see Air Inlet Manifold (255762)

Parts, page 69

112958 NUT, hex, flanged

FLUID CONTROL, assy; see

2

1

11

19

20

21

22

23

24

27

12

13

14

15

16

17

18

Fluid Control Assembly Parts, page 68

255771 BOX, control; see Control Box

(255771) Parts, page 62

256177 SHROUD, front

256178 SHROUD, rear

117623 NUT, cap (3/8-16)

240900 HOSE, coupled, 30 in.

111801 SCREW, cap, hex hd

121471 HINGE, friction, positioning

15T568 DOOR, control shroud

15T567 NUT, backup plate, hinge

112380 SCREW, mach, pan head

054753 TUBE, nylon, round, black; 10 ft

054757 TUBE, nylon, round; 7 ft

C12508 TUBE, nylon, round; 1.3 ft

160327 FITTING, union adapter; 90 deg.

114601 CONDUIT, flexible, non-metallic;

1

3

10

2

1

4

8

1

1

4

2

28

29

3 ft

115313 PLUG, tube

121688 CONNECTOR; 3/8 npt x 3/8

30 tube ptc

108636 MUFFLER

31 114434 GAUGE, pressure, fluid, sst

32  15T468 LABEL, warning

33  LABEL, codes, alerts

15U926 English

 15X126 All languages

34  15W598 LABEL, warning

35  15U656 LABEL, identification

38 293547 LABEL, identification

51

53

15M987 ELBOW; 60 deg.

2

H75003 HOSE, coupled; 1/2-14 npsm; 3 ft 3

1

1

2

1

1

1

1

54 H75002 HOSE, coupled; 1/2-14 npsm; 2 ft 1

55  H53806 HOSE, coupled; 3/8-18 npsm; 6 ft 2

56  15T396 TUBE, recirculation 2

57  551390 SIGHTGLASS, beaker, graduated 10

58 H73825 HOSE, coupled; 3/8-18 npsm; 1

25 ft

8

1

9

1

1

2

2

8

8

1

Ref.


59 15B729 COUPLING; 3/8-18 npsm x 3/8-18 npt

60 15E592 HOUSING, mixer

61  248927 KIT, mixer, element; pack of 25

62 150287 COUPLING; 1/4-18 npsm x 3/8-18

1

63

64

65

75

95



103 npt

H72510 HOSE, coupled; 1/4-18 npsm;

10 ft

XTR704 GUN

162024 COUPLING; 3/8-18 npt x 3/8-18 npt

206995 TSL; 1 qt.

15U655 LABEL, identification

96 15U654 LABEL, identification

100  222200 VALVE, restrictor

101  114593 KNOB

102  156849 PIPE, nipple; 3/8 npt

W30CAS PUMP, solvent, Merkur; see

1

104

105 manual 312794

256169 PLATE, pump, solvent

SCREW, hex hd, flanged

106 112395 SCREW, cap, flanged

107 248208 HOSE, coupled; 4 ft

113 117666 TERMINAL, ground

114 100028 WASHER, lock

115

120

121

122

124 

125 

115901 TRIM, edge

WIRE, ground assy.

WIRE, electric; copper

109025 RING, terminal

LABEL, pressure control

162449 NIPPLE, reducing; 1/2 x 1/4 npt

128 257150 ROD, tie

129 101712 NUT, lock

131 15H392 ROD, adapter

132 244819 COUPLING, assy.

133 244820 CLIP, hairpin with lanyard

134 197340 COVER, coupler

135 113796 SCREW, flanged, hex head

136  114958 TIE, strap

1

10

137  054760 TUBE, polyurethane, black; 3.5 ft.

-

138 256561 PLATE, mounting, solvent pump 1

2

2

2

2

6

6

1

2

2

2

1

1

1

4

1

1

2

139 111799 SCREW, cap, hex head

140 256421 HOSE, siphon, assy.

141 181073 STRAINER, inlet

142 116935 SCREW, cap

143 100081 BUSHING, pipe

144 157350 ADAPTER; 3/8 npt x 1/4 npt

145  15T258 TOOL, wrench, Xtreme

146  159239 NIPPLE, reducing; 1/2 x 3/8 npt

147  16A004 FLASH DRIVE, USB; 4 GB

1

1

1

1

1

1

1

4

1

2

1

2

2

1

1

1

1

1

2

1

1

 Replacement Danger and Warning labels, tags, and cards are available at no cost.

 Not shown.

 Not assembled.

313289B 57

Parts

Parts Varying by Model

XM1_ _ _ and XM2_ _ _ Models

69

70

76

77

Ref.

Part

52

66

67

Description

117623 NUT, cap

L250C4 LOWER, A side; see manual 311762

L250C3

L220C4 LOWER, B side; see manual 311762

L220C3

15H652 LABEL, motor, A side

15H654 LABEL, motor, B side

121295 SCREW, cap, socket head

LABEL, system

XM-50 Plural-Component Sprayer Models

XM1A00 XM1B00 XM1D00 XM1E00 XM2A00 XM2B00 XM2D00 XM2E00

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2 2

1

2

1

2 2 2

1

2

1

2

83

84

85

86

80

81

82

158491 NIPPLE; 1/2 npt

100361 PLUG, pipe

15R529 BLOCK, fluid distribution

156684 UNION, adapter

121139 O-RING; PTFE

15J594 HOUSING, check valve

15J916 HANDLE, blue

87

88

89

15R380 HANDLE, green

255747 CARTRIDGE, valve

24A034 CARRIAGE, remote mix manifold

90

91

92

93

94

245869 HEATER, fluid

245863

256540 BOX, junction

113796 SCREW, flanged, hex head

108

111801 SCREW, cap, hex head

113498 VALVE, relief; 110 psi (0.76

MPa, 7.6 bar)

LABEL, XM50

112

LABEL, XM70

CABLE, CAN, IS, display to

USB; female B/female B

116† 158683 ELBOW, 90 deg.

117 15T967 CABLE, heater

118 116171 BUSHING, strain relief

119 122032 NUT, wire

126 H42506 HOSE, coupled, 4500 psi

127 100527 WASHER

128  224458 STRAINER, pump; 30 mesh (qty. of 2)

1

1

1

1

1

1

2

8

1

4

1

2

2

2

1

5

1

1

1

1

1

1

1

1

2

1

1

1

2

1

8

1

1

1

1

1

1

2

4

1

8

2

2

2

1

5

1

1

1

1

1

1

1

2

1

1

1

2

1

8

† Must purchase when installing fluid heaters on a non-heated sprayer.

 Not shown.

58 313289B

Parts

Parts Varying by Model (continued)


69

70

76

77

Ref.

Part

52

66

67

Description

117623 NUT, cap


L180C3


L145C3


15J692 LABEL, motor, B side


LABEL, system

XM Plural-Component Sprayer Models


1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2 2

1

2

1

2 2 2

1

2

1

2

83

84

85

86

80

81

82


100361 PLUG, pipe



121139 O-RING; PTFE


15J916 HANDLE, blue

87

88

89




90

91

92

93

94


245863



108



MPa, 6.3 bar)

LABEL, XM50

112

LABEL, XM70



116† 158683 ELBOW, 90 deg.



119 122032 NUT, wire


127 100527 WASHER


1

1

1

1

1

1

2

8

1

4

1

2

2

2

1

5

1

1

1

1

1

1

1

1

2

1

1

1

2

1

8

1

1

1

1

1

1

2

1

4

1

8

2

2

2

1

1

1

5 1

1

1

1

2

1

1

1

2

1

8


 Not shown.

313289B 59

Parts



Ref.

Part Description

52 117623 NUT, cap

66 L250C4 LOWER, A side; see manual 311762

L250C3

67 L220C4 LOWER, B side; see manual 311762

L220C3

69 15H652 LABEL, motor, A side

70 15H654 LABEL, motor, B side

76 121295 SCREW, cap, socket head

77 LABEL, system



2

1

2

1

2

1

2

1

2 2 2 2

1

1

1

8

1

1

1

1

8

1

1

1

1

8

1

1

1

8

1

1

1

1

8

1

1

1

1

1

8

1

1

1

1

1

8

1

1

1

1

8

80 158491 NIPPLE; 1/2 npt

81 100361 PLUG, pipe

82 15R529 BLOCK, fluid distribution

83 156684 UNION, adapter

84 121139 O-RING; PTFE

85 15J594 HOUSING, check valve

86 15J916 HANDLE, blue

87 15R380 HANDLE, green

88 255747 CARTRIDGE, valve

89 24A034 CARRIAGE, remote mix manifold

90 245869 HEATER, fluid

245863

91 256540 BOX, junction

92 113796 SCREW, flanged, hex head

93 111801 SCREW, cap, hex head

94 113498 VALVE, relief; 110 psi (0.76

MPa, 7.6 bar)

108 LABEL, XM50

112

LABEL, XM70



116† 158683 ELBOW, 90 deg.



119 122032 NUT, wire


127 100527 WASHER

128  224458 STRAINER, pump; 30 mesh

(qty. of 2)

4

2

2

2

2

2

1

1

2

1

1

8

1

1

1

1

4

2

2

2

2

2

1

1

2

1

2

1

1

2

2

2

4

8

1

1

5

8

1

1

8

1

2

1

2

2

2

2

1

4

1

2

1

1

1

2

1

2

2

2

2

1

4

1

2

1

2

1

8

1

1

2

8

1

4

2

2

2

2

2

1

1

2

1

1

8

1

1

1

4

2

2

2

2

2

1

1

2

1

2

2

2

2

4

8

1

1

5

1

1

8

1

8

1

2

1

2

2

2

2

1

4

1

2

1

1

1

8

1

2

1

2

2

2

2

1

4

1

2

1

2

1

2

8


 Not shown.

60 313289B

Parts



69

70

76

77

Ref.

Part

52

66

67

Description

117623 NUT, cap


L180C3


L145C3


15J692 LABEL, motor, B side


LABEL, system



2

1

2

1

2

1

2

1

2 2 2 2

1

1

1

8

1

1

1

1

8

1

1

1

1

8

1

1

1

8

1

1

1

1

8

1

1

1

1

1

8

1

1

1

1

1

8

1

1

1

1

8

83

84

85

86

80

81

82


100361 PLUG, pipe



121139 O-RING; PTFE


15J916 HANDLE, blue

87

88

89




90

91

92

93

94


245863



108



MPa, 6.3 bar)

LABEL, XM50

112

LABEL, XM70



116† 158683 ELBOW, 90 deg.



119 122032 NUT, wire


127 100527 WASHER


4

2

2

2

2

2

1

1

2

1

1

8

1

1

1

1

4

2

2

2

2

2

1

1

2

1

2

2

2

2

4

8

1

1

5

8

1

1

1

1

8

1

2

1

2

2

2

2

1

4

1

2

1

1

1

2

1

2

2

2

2

1

4

1

2

1

2

1

8

1

1

2

8

1

4

2

2

2

2

2

1

1

2

1

1

8

1

1

1

4

2

2

2

2

2

1

1

2

1

2

2

2

2

4

8

1

1

5

1

1

8

1

8

1

2

1

2

2

2

2

1

4

1

2

1

1

1

8

1

2

1

2

2

2

2

1

4

1

2

1

2

1

2

8


 Not shown.

313289B 61

Parts

Control Box (255771) Parts

Air Power and Electric Power Versions

204g

204a, 204d

236

214

219b

251

223

202

220

219a

222

202

235

242

209

218

243

232 238

239

204b

201

243

227

232

226

204f

204h

204e

241

221

237

238

204c

240

244

245

208

226

201

243

230

228

229

215

210

242

233

226

234

217

224, 225

219c

Ref.


201

202

BOX, control

LABEL, control display

204 257484 MODULE, display, kit

204a 15M483 SHIELD, membrane, display (qty.

10)

204b SCREW, pan head; #6 x 7/8 in.

204c 288997 CASE, rear, display module, IS

1 version

204d 255727 CASE, front, data module 1

204e 277463 COVER, access, low level display 1

204f 113768 SCREW, socket, flat head

204g 15R458 GASKET, control, front panel

 204h 15W958 LABEL, warning, battery

208 SCREW, pan head

1

4

4

1

4

1

1

1

Ref.

Part

210

214

217

218

Description

209 256555 MODULE, solenoid, IS version

209a 121636 VALVE, solenoid, din connector

209b 15A789 GASKET, solenoid, outlet

209c 15A799 GASKET, solenoid, inlet/exhaust

106084 SCREW, machine, pan head

15R379 GASKET, box, control

215 LABEL

216  15B056 LABEL, air motor/dosing valve

122000 ALARM, panel mount

255920 MODULE, fluid control

219b 289900 MODULE, USB

219c 277674 DOOR, module r_xm1a00_312359_313289_6a-1

Qty.

1

1

2

1

1

1

1

1

1

4

219 257088 MODULE, USB, assy.

219a 289899 BASE 1

1

1

62 313289B

Parts

Ref.


220 121618 SWITCH, start, push button, green

221 15R324 HARNESS, USB, plug/bulkhead;

1

1

32 in.

222 121619 SWITCH, stop, push button, red 1

223 121617 SWITCH, 2 position, key, controls 1

223a  123412 KEY, replacement (pair)

224 117745 BUSHING, strain relief 1

225 117625 NUT, locking

226 113505 NUT, keps, hex head

227 15B090 WIRE, grounding, door

228 558685 WASHER, lock, external

229 15R343 CLAMP, ground, electrical

230 065213 WIRE, copper, elect

231  172953 LABEL, designation

232 120493 LATCH, mounting

233 15H189 BOOT, wire feed through

234 15G816 COVER, plate, wire

235 110637 SCREW, machine, pan head

236 15R325 COVER, dust, bulkhead

4

1

1

1

2

3

1

3

1

1

1

6

237

238 receptacle

120495 BLOCK, switch, n.c.

120494 BLOCK, switch, n.o.

239 15M974 HARNESS, key switch

240 15M975 HARNESS, start/alarm

241

242

15M976 HARNESS, stop

15M977 HARNESS, solenoid

243 121988 RETAINER, routing, wire harness 4

244 195875 SCREW, machine, pan head 1

1

2

1

1

1

2

245 102063 WASHER, lock

246  15U542 CABLE, motor

251  LABEL, warning, USB

15X214 English

15X393 All languages

252  122829 CONDUIT; 0.75 ft.

1

2

1

-


 Not shown.

313289B 63

Parts

Control Box Power Supply Options

Alternator Assembly

263

262, 263

260

261

265

Ref.


260 15B090 WIRE, grounding, door

261 100284 NUT, hex

262 102063 WASHER, lock; carbon steel

263 110637 SCREW, machine pan head

264  C12508 TUBING, round; nylon; 5.0 ft

265

255728 ALTERNATOR, module; see page

70

266 15V778 CABLE, CAN, IS, female B/female

B; 20 in.

267 15V782 CABLE, CAN, IS, male B/female B;

20 in.

268 15V783 CABLE, CAN, IS, female A/male B;

39 in.

Qty.

1

1

1

5

1

1

1

1 r_256991_313293_7a

Air Regulator Assembly

Alternator Assembly Cable Connections

282

276

266

267

277

279

278

281

280 r_256991_313293_1a

Ref.


276 156971 NIPPLE, short; 2 x 1/4-18 npt

277 115243 REGULATOR, air; 1/4 npt

278 112307 ELBOW, union; 90 deg.; 1/8 npt(f) x

1/8 npt(m); carbon steel

279 15W017 VALVE, safety, regulator

280 115841 ELBOW, swivel, male; 1/4 npt

281 104655 GAUGE, air pressure

282 156823 SWIVEL, union; 2 x 1/4-18 npt

Qty.

1

1

1

1

1

1

1

268 r_256991_313293_9

64 313289B

Parts

Wall Power Supply Assembly

r_256991_313293_3a1

273

270

273

263

262

260

271

272

Wall Power Supply Assembly Cable Connections

Ref.


262 102063 WASHER, lock; carbon steel



B; 20 in.

270 15V747 POWER SUPPLY; 24V, 2.5A, 60W

271 115306 FILTER, power supply

272  CABLE, power, control box

272a  15X407 CABLE, power, US plug

272b  15Y685 CORD; 240V, 10A, IEC320

195551 RETAINER, adapter, cord

242001 CORD, set, adapter, Europe

242005 CORD, set, adapter, Australia



B; 39.4 in.

Qty.

1

3

1

1

1

1

1

1

1

1

1

4

1

 Used on XM_A_ _ models only.

 Not shown.

266

313289B

274 r_256991_313293_10

65

Parts

Air Controls Module (255761) Parts

326

317

307

313

303

316 344

308

310

311

Ref. 94

345

342

312

309

315

336

332

337

332

329

319 338

335

317

313

346 347

318

330

325

327

328

333

335

329

334

340

331

327 318

Ref.


303 157350 NIPPLE, pipe; 1/2 x 3/8 npt

304 108307 ELBOW, pipe, male

306 101689 GAUGE, press, air

307 117346 VALVE, ball, vented

308 114316 ELBOW, male, swivel


310 158962 ELBOW, street; 1/4(f) x 1/8(m)

311 116643 VALVE, safety, relief, air

312 100721 PLUG, pipe

313 119992 PIPE, nipple; 3/4 x 3/4 npt

315 156589 ADAPTER, union; 90 deg.

316 113911 GAUGE, pressure, air

317 160327 ADAPTER, union; 90 deg.

318 15T119 LABEL, control

319 BRACKET, air controls

320 15R437 BRACKET, adapter, air controls

321 121432 SCREW, machine, hex flat head

322 115942 NUT, hex, flange head

325 116513 REGULATOR, air

326 121457 VALVE, ball, air, panel mounted

327 121424 GAUGE, pressure, panel mount,

1.5 in.

328 100451 COUPLING


330 100264 SCREW, machine, pan head

331 116514 NUT, regulator

Qty.

1

1

1

2

2

1

1

3

2

1

1

1

1

1

2

4

1

2

2

1

1

2

1

1

2

333

306

321

343

342

322

304

341

320

Ref.


332 054760 TUBE, polyurethane, round, black;

1.25 in.

333 TUBE, polyurethane, round; 0.6 ft.

334 100840 ELBOW, street

335 162453 FITTING; 1/4 npsm x 1/4 npt



338 164259 ELBOW, street

340  122336 NUT, panel, regulator

341  113440 ADAPTER

342  113431 CLAMP, quick

343  113442 BLOCK, porting

344  15R488 REGULATOR

344a 123454 FILTER, element; 5 micron

345  15R487 REGULATOR

346  15R486 MUFFLER

347  15R485 VALVE, dual pilot

Qty.

-

1

1

1

1

1

4

2

1

2

1

1

2

1

1

-

 Parts included in Air Controls Kit 255772 (purchase separately).

66 313289B

Parts

Junction Box (256540) Parts

417

422

432

415

419

430

431

426

405

427

432

401

431

402

435

416

425

430

433

422

434

410

420

417

413

414

439

412

411

407

437

427

419

421

404

403

Ref.


401 ENCLOSURE, electrical

402 117545 KNOB, operator disconnect

403 117564 SWITCH, disconnect; 100A

404 117553 SWITCH, disconnect, phase expander; 100A

405 15U423 SWITCH; 25A 4

406 255047 BUSHING, strain relief, m40 thread 1

407 255048 NUT, strain relief; M40 thread



410 117625 NUT, locking

1

1

1

2

411 15U543 PLUG, hole; 7/8 in.

412 15U544 PLUG, hole; 1 1/8 in.

413 117666 TERMINAL, ground

414 115942 NUT, hex, flange head

415

416

RAIL, mounting; 3 in.

RAIL, mounting

417 255045 BLOCK, clamp end

419 COVER, end

4

2

1

1

1

1

1

3

420 255050 CIRCUIT BREAKER; 25A

421 121623 CIRCUIT BREAKER; 10A

422 120570 BLOCK, terminal

425 BAR, power bus, 6 pin

426 117679 CONNECTOR, power lug

427 120573 BRIDGE, plug-in

9

1

2

2

2

4

1

1

1

1

408

409 406 r_312359_313289_38

Ref.


428  15U954 HARNESS, junction box

430 113505 NUT, keps, hex head

431 15U662 LABEL, identification

432 MARKER, block, terminal

433 MARKER, block, terminal

434 112948 SCREW, machine head

435 100166 NUT, full hex

436  15R344 LABEL, identification, wiring

437  196548 LABEL, caution

438  SCHEMATIC, wiring

439 558685 WASHER, 1/4 external

Qty.

1

1

2

1

1

2

1

4

1

1

1


 Not shown.

313289B 67

Parts

Fluid Control Assembly Parts

501

507

509

502

506

505

504 r_312359_313289_36

503

508

504

510

511 r_312359_313289_37

Ref.


501  255478 VALVE, dosing

502‡ 245143 VALVE, sampling

503  15R381 HANDLE, valve, recirculation

(black)

504  * 255747 CARTRIDGE, valve, check

505  15J594 HOUSING, valve, check

505a 121139 O-RING, valve; PTFE

506

507

15R347

15M669

SENSOR, RTD

SENSOR, fluid, pressure

507a 121399 O-RING, transducer, pressure

508  255684 MANIFOLD, mix, assy

509  VALVE, restrictor, assy

510  214037 VALVE, solvent, shutoff, assy

511  HANDLE, valve, mix manifold

(blue and green)

Qty.

2

2

2

2

1

2

2

4

2

2

1

1

2

 See Dosing Valve manual 313342 for more information.

‡ See Xtreme Displacement Pumps manual 311762 for more information. Repair kit 245145 is available for order.

 See High Flow Severe Duty Shutoff Check Valve manual 313343 for more information.

 See XM Mix Manifold Kits manual 312749 for more information and part numbers.

* Seal kit 256239 is available for order.

68 313289B

Parts

Air Inlet Manifold (255762) Parts

617

616

611

616

607

613

617

616

611

611

602

602

605

609

601

610

604

Ref.


606

607

608

609

610

611

614

616

617

601

602

207675 MANIFOLD, air

119992 PIPE, NIPPLE; 3/4 x 3/4 npt

603 15E145 MANIFOLD, air distribution

604 117628 FILTER, air, auto drain; 3/4 npt

604a  106204 ELEMENT, filter; 3/4 npt

605 122327 ELBOW, pipe, male

113218 VALVE, ball, vented

157785 SWIVEL

156172 UNION, swivel

100509 PLUG, pipe

114234 PLUG, hex head

155699 ELBOW, street

166590 ELBOW, street

157350 ADAPTER

115781 CAP PLUG

 Not shown.

Qty.

1

1

1

2

1

3

1

1

1

1

1

1

3

2

606

608

614 r_xm1a00_312359_313289_21a

313289B 69

Parts

Alternator Module (255728) Parts

707

708

710

702

703

701 r_255278_313289a

706

708

711

701

704

705

Ref.


701

702

HOUSING, upper and lower

GASKET, stacked, internal

703 GASKET, housing

704 257147 TURBINE

705 BOARD, assy.

706 122161 FITTING, air

707  15R337 LABEL, warning

708 114380 SCREW, cap, socket head

709  C12508 TUBING, nylon; 2 ft.

710 122848 FITTING, air

711  172953 LABEL, grounding

Qty.

1

7

1

1

1

1

1

1

-

1

1


 Not shown.

70 313289B

Parts

Repair and Spare Parts Reference

NOTE:

Part numbers and sub-assemblies may change. See www.graco.com for most current part numbers and manuals.

Part

256239

223016

16A004

15M483

121636

123412

123454

234098

234131

245143

245145

121139

121399

256238

551387

114434

185416

121410

15T630

214037

106204

257147

244851

L220C4

244902

244852

L145C4

244900

244850

224458

224459

24B732

244895

24B733

244895

15T258

206995

255747

257055

NXT600

NXT135

NXT136

256893

15E592

248927

XTR704

XHD001

XHDxxx

L250C4

244903

244853

L180C4

244901

Ref.

501b

502

502a

505b

507b

508a

508b

508c

88a

100a

147

204a

209a

223a

344a

501a

508d

508e

508f

510

604a

704

67a

67b

67b

67b

67b

72

75

88

66

67

67

67

67

67

67

67a

66

66

66

66

64

64a

64b

66

2

2

2

2

2a

60

61

Description

NXT Motor w/linear transducer

Motor seal kit

Air Valve seal kit

Air valve rebuild kit

Linear sensor

Mixer housing, no mixer; 1/2 in. ID, 3/8 nptm

Mixer sticks; 1/2 in. x 12 element, package of 25

XTR spray gun; 7250 psi; includes 519 RAC tip

RAC guard, housing, replacement

RAC tip, seal, gasket, x indicates tip size

Xtreme displacement pump L250C3 w/o filter

Repair kit with Tuff Stack

Repair kit with Xtreme seals







Xtreme displacement L145C3 w/o filter



Filter screens; 30 mesh, package of 2 (optional)

Filter screens;60 mesh, package of 2 (optional)

Filter o-rings, solvent resistant rubber, package of 10 (optional)

Filter o-rings; PTFE, package of 10 (optional)

Filter o-rings; solvent resistant rubber, package of 10 (optional)

Filter o-rings; PTFE, package of 10 (optional)

Wrench, Xtreme pump

TSL; quart bottle

Cartridge, circulation, shut-off, mix manifold valves

Seal kit for cartridge valves

Repair kit for b/p restrictor valve

Flash drive for USB download; 4 GB

Membrane shields, package of 10

Solenoid valve, individual replacement valve with DIN

Spare key; one pair

Control filter; 5 micron, replacement element

Seal kit; include soft parts, old and new dosing valve

Rebuild kit; includes seals, stem, seat, and air spring

Sample valve; complete valve

Sample valve kit; includes o-rings, ball, seat, clip

Circulation valve seal; face o-ring, -210, PTFE

Transducer seal; o-ring, -012, solvent resistant rubber

Repair kit; includes seals, balls, seats, shut-off stems

Fluid gauge, bottom mount; 10,000 psi (690 bar)

Fluid gauge, back mount; 10,000 psi (690 bar)

B-side strainer; 40 mesh (use tool 15T630)

Strainer o-ring; PTFE, -113, strainer restrainer

Strainer tool (push in 121410 o-ring + shut-off u-cup)

Flush valve, ball; 1/4 npt(m) PTFE

Main air filter, element (fits 3/4 npt air filters)

Turbine cartridge (fits 255728 XM or Xtreme Mix)

Qty.

2

1

1

1

2

2

2

2

1

2

4

1

4-6

2

1

1

1

1

1

1

1

1

2

1

1

4-6

4

2

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

Part of Assembly

Shut-off/check

System

Control

Control

Control

Controls

Air controls;

Dosing valve

Dosing valve

Dosing valve

Dosing valve

Dosing valve

Dosing valve

Mix manifold

Mix manifold

Mix manifold

Mix manifold

Mix manifold

Mix manifold

Mix manifold

Air controls

Control

Motor

Motor

Motor

Motor

Motor

System

System

System

System

System

XM50 "A" pump

XM50 "A" pump

XM50 "A" pump

XM70 "A" pump

XM70 "A" pump

XM70 "A" pump

XM50 "B" pump

XM50 "B" pump

XM50 "B" pump

XM70 "B" pump

XM70 "B" pump

XM70 "B" pump

Pump

Pump

Pump

Pump

Pump

Pump

System

System

Shut-off/check

313289B 71

Accessories and Kits

Accessories and Kits

Not all accessories and kits are approved for use in hazardous locations. Refer to the specific accessory and kit manuals for approval details.

20-Gallon Hopper Kit, 255963

One complete double-wall 20-gallon hopper. See manual 312747 for more information.

5:1 Feed Pump Kit, 256276

For supplying viscous materials from a 20-gallon hopper to an XM sprayer. See manual 312769 for more information.

Hopper Heater Kit (240V), 256257

For heating fluid in a 20-gallon hopper. See manual

312747 for more information.

7-Gallon Hopper and Bracket Kit, 256260

One 7-gallon hopper and mounting brackets. Mounts to the side or back of an XM sprayer. See manual 406999 for more information.

Universal Hopper Fluid Inlet Kit, 256170

For connecting any of the four lower models included with XM sprayer to a 20-gallon hopper. See manual


2:1 Drum Feed Kit, 256232

One T2 pump feed kit and one Twistork agitator kit for mixing and supplying viscous materials from a with

55-gallon drum to an XM sprayer. See manual 312769 for more information.

Universal Hopper Mounting Kit, 256259

For mounting a 20-gallon hopper to the side or back of an XM sprayer. See manual 312747 for more information.

5:1 Drum Feed Kit, 256255

One 5:1 pump feed kit and one Twistork agitator kit for mixing and supplying viscous materials from a with

55-gallon drum to an XM sprayer. See manual 312769 for more information.

Twistork Agitator Kit, 256274

For mixing viscous materials held within a 20-gallon hopper. See manual 312769 for more information.

T2 Feed Pump Kit, 256275

For supplying viscous material from a 20-gallon hopper to an XM sprayer. See manual 312769 for more information.

Hopper/Hose Heat Circulation Kit, 256273

For circulating heated water mixture through 20-gallon hoppers, heated hose, and Viscon HP heater. See manual 313259 for more information.

Desiccant Dryer Kit, 256512

For use with 20-gallon hoppers. See manual 406739 for more information.

72 313289B

Accessories and Kits

Caster Kit, 256262

For mounting casters on XM sprayer frame. See manual


10:1 Drum Feed Kit, 256433

For supplying highly viscous material from a 55-gallon drum to an XM sprayer. See manual 312769 for more information.

Hose Rack Kit, 256263

For mounting to side, front, or back of XM sprayer frame.

See manual 406691 for more information.

Shutoff/Check Valve Kit, 255278

For replacing shutoff valve or check valve. See manual


Lower Strainer and Valve Kit, 256653

For straining material from a feed pump to an XM sprayer fluid inlet. See manual 312770 for more information.

Alternator Conversion Kit, 256991

For converting an XM sprayer from wall power supply to intrinsically safe alternator power supply. See manual


Electric Heated Hose Power Supply Kit,

256876

For monitoring and controlling fluid temperature in low-voltage heated hoses. See manual 313258 for more information.

Mix Manifold Kit, 255684

See manual 312749 for more information.

Remote Mix Manifold and Carriage Kit,

256980

For converting to a remote mix manifold kit with a protective guard. See manual 312749 for more information.

5000 psi Two-Component Main Heated

Hose Set Kit

Electric heated hose set for adding additional sections.

Part

248907

248908

Description

Heated hose set; 1/4 in. ID x 3/8 in. ID;

50 ft.

Heated hose set; 3/8 in. ID x 3/8 in. ID;

50 ft.

Level Sensor Adapter Kit, 256261

For monitoring level of spray material inside 20-gallon hopper. See manual 406740 for more information.

Xtreme Pump Wet Cup Wrench, 15T258

313289B 73

Dimensions

Dimensions

System Dimensions without Hoppers

39.5 in.

(1003.3 mm)

70.0 in.

(1788.0 mm)

36.0 in.

(914.4 mm) r_xm1a00_312359_313289_12a

38.0 in.

39.5

) r_312359_313289_b_2

74 313289B

Dimensions

System Dimensions with Hoppers

Two 20-Gallon Hoppers

Side Mounted


Rear Mounted

(Top View)

98.6 in.

98.6

)

54.0 in.

(1371.6 mm) 49.7 in.

(1262.4 mm)

( 72.5

)

72.5 in.

(1841.5 mm)

( 43.1

43.1 in.

)

(1094.7 mm) r_312359_313289_b_3

62.8 in.

(1595.1 mm)

313289B

38.4 in.

(975.4 mm)

56.2 in.

(1427.5 mm) r_xm1a00_312359_313289_13a

75

Dimensions

System Dimensions with Hoppers

One 20-Gallon Hopper and One 7-Gallon Hopper

72.5 in.

72.5

)

43.1 in.

43.1

)

79.1 in.

(2009.1 mm)

( 79.1

)


76

70.0 in.

(1788.0 mm)

( 33.4

)

33.4 in.

(848.4 mm) r_312359_313289_b_5

59.7 in.

(1516.4 mm)

70.0 in.

(1788.0 mm)

33.4 in.

(848.4 mm) r_312359_313289_b_4

313289B

Technical Data

Technical Data

Mixed ratio range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1-10:1 (in 0.1 increments)

Ratio tolerance range (before alarm) . . . . . . . . . . . . . . . . +/- 5%

Flow rates

Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 qt./min. (0.95 liter/min.)*

3 gal./min/ (11.4 liter/min.)

Fluid viscosity range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-20,000 cps (heavier viscosities can be mixed using heat, circulation, and/or pressure feeding)

Fluid filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mesh, (238 micron) standard on pump outlets (filter assembly not included on some models)

Air inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt(f)

Fluid inlets without feed kits . . . . . . . . . . . . . . . . . . . . . . . 1 1/4 npt(m)

Maximum fluid working pressure of mixed material

50:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5200 psi (35.8 MPa, 358 bar)

6300 psi (43.5 MPa, 435 bar)

Maximum fluid temperature . . . . . . . . . . . . . . . . . . . . . . . 160° F (71° C)

Air supply pressure range. . . . . . . . . . . . . . . . . . . . . . . . . 50-150 psi (0.35-1.0 MPa, 3.5-10.3 bar)

Maximum pump air set pressure

50:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105 psi (0.74 MPa, 7.4 bar)

85 psi (0.60 MPa, 6.0 bar)

Maximum pump inlet fluid feed pressure . . . . . . . . . . . . . 250 psi (1.7 MPa, 17 bar)

Maximum air consumption at 100 psi (0.7 MPa, 7.0 bar) in scfm (m

3

/min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 scfm per gpm (1.96 m

3

/min. per lpm)

Ambient temperature range

Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32-135° F (0-57° C)

30-160° F (-1-71° C)

Environmental conditions rating . . . . . . . . . . . . . . . . . . . . Indoor/outdoor use

Altitude up to 4000 m

Maximum relative humidity to 99% up to 130° F (54° C)

Pollution degree (11)

Installation category (2)

Sound pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 dBA at 100 psi (0.7 MPa, 7 bar)

Sound power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 dBA at 100 psi (0.7 MPa, 7 bar)

Wetted parts

Suction tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flush pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pumps (A and B) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

aluminum carbide, PTFE, stainless steel, UHMWPE nylon carbon steel, alloy steel, 303, 440, 17-ph grades stainless

Metering valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

steel, zinc and nickel plating, ductile iron, tungsten carbide, PTFE carbon steel, nickel plating, carbide, polyethylene, leather carbon steel, nickel plating, carbide, 302 stainless steel,

Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spray gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PTFE, UHMWPE stainless steel housing with acetal elements

Refer to spray gun manual

Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Dimensions, page 74

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Base sprayer (XM1A00 and XM5A00 models)

742 lbs (336.87 kg)

(Add component weight(s) to base sprayer weight for your specific model weight. See component manuals.)

* Minimum flow rate is dependent on material being sprayed and mixing capability. Test your material specific to flow rate.

313289B 77

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

For the latest information about Graco products, visit www.graco.com.

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.

This manual contains English. MM 313289

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

Copyright 2009, Graco Inc. is registered to ISO 9001 www.graco.com

Revised 9/2009

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