Graco 309518P User Manual

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Repair

™

Xtreme Mix

Plural Component Proportioner For spraying two-component protective coatings.

Not approved for use in explosive atmospheres.

Important Safety Instructions

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

See page 3 for model information, including maximum working pressure and approvals.

309518P

ENG

Contents

Xtreme Mix Models . . . . . . . . . . . . . . . . . . . . . . . . . 3

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 4

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 7

Proper Lifting of Unit . . . . . . . . . . . . . . . . . . . . . . . . 8

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Metering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Turbine Alternator . . . . . . . . . . . . . . . . . . . . . . . . 9

Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Replacing Air Filter Element . . . . . . . . . . . . . . . 16

User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Pneumatic Control . . . . . . . . . . . . . . . . . . . . . . 20

Pump Air Manifold . . . . . . . . . . . . . . . . . . . . . . . 22

Sampling Valve . . . . . . . . . . . . . . . . . . . . . . . . . 23

Metering Valve/Manifold Assembly . . . . . . . . . . 24

Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . 28

Pneumatic Schematic . . . . . . . . . . . . . . . . . . . . . . 30

Pneumatic/Sensor Connections . . . . . . . . . . . . . 31

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Metering Valve Manifold 245824 . . . . . . . . . . . . 41

Metering Valve Manifold 248843 . . . . . . . . . . . . 41

Sampling Valve 245143 . . . . . . . . . . . . . . . . . . 41

Repair Kit 249406 . . . . . . . . . . . . . . . . . . . . . . . 41

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 48

2 309518P

Xtreme Mix Models

WARNING

Do not install equipment approved only for non-hazardous location in a hazardous area. Substitution of components may impair intrinsic safety. See page 5.

Approved for Non-hazardous Location

Xtreme Mix Models

Xtreme

Mix

Part No. Series

233863 A 249274 45:1 King 4500 (31, 310) 233864 A 249275 56:1 King 5600 (38.6, 386) 233865 A 249276 68:1 King 6800 (46.9, 469) 233866 A 249277 80:1 King 7250 (50, 500) 233867 A 249278 45:1 Quiet King 4500 (31, 310) 233868 A 249279 56:1 Quiet King 5600 (38.6, 386) 233869 A 249280 68:1 Quiet King 6800 (46.9, 469) 233870 A 249281 80:1 Quiet King 7250 (50, 500)

*248842 A 249276 68:1 King

*Model 248842 is designed for remote feed pumps and a remote mix manifold. It does not include hoppers, mix

manifold, hose, or spray gun. Refer to manual 310794 for application layout.

Model 248842 is limited to 5000 psi (34.5 MPa, 345 bar) for use in “quick set” packages where heated hoses, whip hoses, and spray accessories are limited to 5000 psi (34.5 MPa, 345 bar). If all your downstream components are rated for 7000 psi (48 MPa, 483 bar), you can replace the standard relief valve with relief valve

113498.

Pump

Part No.

Pump

Description

Remote Mix

Maximum Working

Pressure

psi (MPa, bar) Approvals

5000 (34.5, 345)

309518P 3

Manual Conventions

WARNING

Hazard Symbol

Note

Additional helpful information.

WARNING: a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Warnings in the instructions usually include a symbol indicating the hazard. Read the general Warnings section for additional safety information.

CAUTION

CAUTION: a potentially hazardous situation which, if

not avoided, may result in property damage or destruction of equipment.

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 catalyst (curing agent) or minor

volume.

Related Manuals

Component Manuals This manual available in following languages:

Manual Description

309535 Xtreme Mix Operation 311762 Xtreme Displacement Pump 309347 King Air Motor

or 309348 King Quiet Air Motor

312145 XTR Spray Gun 309524 VISCON HP Heater 309525 Heated Hose Kit 308981 Husky 716 Diaphragm Pump 309615 Heater Bracket Kit 309568 Remote Manifold Kit 310797 Remote Mix Manifold 310794 Remote Mix Proportioning Systems 310863 Feed and Flush Kits 309827 Air Supply Kits

Manual Language Manual Language

309518 English 309609 Italian 309564 French 309610 Finnish 309565 Brazilian

Portuguese 309566 Spanish 309612 Chinese 309567 German 309613 Korean 309608 Greek 309614 Japanese 310752 Dutch 310753 Norwegian 310777 Danish

309611 Swedish

4 309518P

Warnings

The following general warnings are related to the safe setup, use, grounding, maintenance, and repair of this equipment. Additional more specific warnings may be found throughout the text of this manual where applicable.

Warning

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground equipment and conductive objects in work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

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

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

309518P 5

Warning

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-

ponent. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings.

• Check equipment daily. Repair or replace worn or damaged parts immediately.

• Do not alter or modify equipment.

• For professional use only.

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

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

• Do not kink or overbend hoses or use hoses to pull equipment.

• Comply with all applicable safety regulations.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

TOXIC FLUID OR FUMES HAZARD

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

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

RECOIL HAZARD

Gun may recoil when triggered and cause you to fall and be seriously injured if you are not standing securely.

6 309518P

Pressure Relief Procedure

WARNING

Follow Pressure Relief Procedure when you stop spraying and before cleaning, checking, servicing, or transporting equipment. Read warnings, page 5.

1. Engage trigger lock.

2. Press Stop .

SUPPLY AIR PRESSURE

PLURAL COMPONENT PROPORTIONER

3. Close main air shutoff valve on air supply line and on unit. Turn off air regulator.

4. Close fluid sampling and shutoff valves A and B.

6. Hold a metal part of the gun firmly to a grounded metal pail. Trigger gun to relieve pressure.

TI5046A

7. Engage trigger lock.

8. Place waste container under sampling valves, then open valves A and B slowly to relieve pressure between pump and metering valve.

Open

PSI Bar MPa

5. Disengage trigger lock.

9. Close sampling valves A and B.

Close Close

309518P 7

Proper Lifting of Unit

WARNING

Follow instructions below to avoid dropping or swinging unit or being struck by the cart handle, which can cause serious injury or damage to equipment.

Either remove the cart handle or secure it to the cart before lifting the unit. Connect a bridle swing, hooking an end to each of the Xtreme Mix air motor rings. Hook the center ring on a hoist. See F Xtreme Mix unit; make sure it balances evenly.

IG. 1. Carefully lift the

Grounding

WARNING

Read warnings, page 5.

If the Xtreme Mix ground wire clamp (G) is disconnected during repair, be sure to reconnect it to a true earth ground before starting operation.

FIG. 1

IG. 2

8 309518P

Shutdown

Follow this procedure before prolonged shutdown or servicing equipment.

If your system includes heaters and heated hose, make sure they are turned off and cool before flushing.

1. Follow Pressure Relief Procedure, page 7. Engage

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

PSI Bar MPa

2. Follow Full System Flushing procedure in the

Xtreme Mix Operation manual.

TI5193

Maintenance

Metering Valve

• Fill metering valves A and B packing nuts (627) with throat seal liquid (TSL) and tighten 1/4 turn after nut contacts packings; about 145-155 in/lbs (16-18 N•m). Check packing nut tightness after first hour of operation, again after 24 hours, then check as needed (when TSL discolors or seeps over packing nut). Also check tightness whenever unit is transported.

• Recommend that you replace metering valve packings every other time that pump packings are replaced.

627

3. Follow Pressure Relief Procedure, page 7.

Engage trigger lock.

4. Before prolonged shutdown: cap fluid outlets to keep solvent in the lines. Fill pump A and B packing nuts with throat seal liquid (TSL); follow instructions in pump manual.

Pump

See pump manual.

Turbine Alternator

Replace bearings every 2000 hours. See page 20.

Air Filters

Check daily. Drain and clean as necessary. See page

16.

309518P 9

Pump Test

Follow this procedure the first time system is operated (after flushing and priming) and whenever you need to check whether pumps are on ratio.

The following table shows the volume dispensed during the pump test, based on your pump ratio. Dispense into a container with adequate graduations.

Pump Volume Dispensed

45:1 750 cc 56:1 660 cc 68:1 540 cc 80:1 435 cc

1. Turn knob to pump test . Turn off air regulator. Open main air shutoff valve. Adjust air pressure to 50 psi (0.35 MPa, 3.5 bar).

c. Press Start . Pump A light comes on.

d. Slowly open and adjust sampling valve A to

achieve desired flow. The pump stops automatically when dispense is complete. Pump A light turns off, Pump B light comes on.

PSI Bar MPa

Open

PSI Bar MPa

2. Dispense fluid A: a. Close fluid shutoff valves and sampling valves A

and B.

b. Place a clean 1 quart (1000 cc) container under

sampling valve A.

a. a. b.

3. Close sampling valve A.

4. Dispense fluid B as follows: a. Place a clean 1 quart (1000 cc) container under

sampling valve B.

b. Slowly open and adjust sampling valve B to

achieve desired flow. The pump stops automatically when dispense is complete. Pump B light turns off.

Open

10 309518P

5. Close sampling valve B.

6. Compare fluid amounts in the containers; they should be equal. Repeat test if fluids are not equal. If problem still persists, see Troubleshooting, page

12.

Pump Test

309518P 11

Troubleshooting

WARNING

If an error code displays, see page 15.

Read warnings, page 5.

Problem Cause Solution

Display not lit. No electric power.

Pumps do not run.

Pump test volume is not correct. Air pressure to pumps too low Increase pressure to 50 psi (0.35 MPa,

Air valve not turned on. Turn on main air valve to system. Air supply pressure too low. Increase pressure to 50 psi (0.35 MPa,

3.5 bar) or greater.

Air supply filters plugged. Clean filter bowls; replace filter elements.

Page 16. Turbine air regulator set too low. Adjust to proper setting. Turbine alternator failure. Repair or replace turbine. Page 20. Power supply not connected to main

board. Main board not connected to display

board.

Display board failure. Replace display board. Page 18.

Knob set to cycle counter Air pressure to pumps too low Increase pressure to 50 psi (0.35 MPa,

Air pilot lines are obstructed Check pilot lines for kinks or pinches. Solenoid valve stuck. Actuate solenoid manually, if it does not

Air pilot valve(s) to motor stuck. Replace valve(s). Page 22. Metering valve(s) not opening. Service or replace valve(s). Page 24.

Sensors not functioning properly. Check position of sensors. See page 27.

Pump cavitating excessively. Check for air in lines caused by loose fit-

Check power connections to main board.

See Electrical Schematic, page 28.

Check electrical connections between

display and main board. See Electrical

Schematic, page 28.

Set knob to desired setting.

3.5 bar) or greater.

operate, replace solenoid. Page 21.

3.5 bar) or greater.

Check board calibration and recalibrate if

necessary. See page 19.

Replace sensors. Page 27.

ting or use of agitator.

Material too viscous. Use heater.

12 309518P

Troubleshooting

Problem Cause Solution

Paint does not cure consistently. Ratio not set correctly. Check that correct ratio is set and set by

volume. See Xtreme Mix Operation manual.

Material not mixing correctly. Test pump. Page 10.

Make sure mixer is clean; flush as needed. See Xtreme Mix Operation manual.

Pump not operating correctly. Observe whether pumps are loading and

checking correctly, if not, clean and repair pump. See pump manual.

Poor spray pattern. Fluid pressure too low. Increase pump pressure.

Spray tip dirty or worn. Relieve pressure. Clean or replace tip.

Follow gun manual instructions. Fluid A or B filters plugged. Clean filters. See pump manual. Mixer or hoses partially plugged or too

restrictive.

System runs erratically. Air filter(s) clogged. Replace elements. Clean. Replace element(s). See page 16.

Air supply hoses undersized. Replace hoses with appropriate size. Air compressor undersized. Use larger air compressor. Air supply pressure tank undersized. Use larger pressure tank.

Air supply relief valve opens. Turbine air regulator set too high. Lower setting to 23-25 psi (172-241 kPa,

Turbine alternator makes high-pitched whining noise.

Display shows 88888 or unit reboots unexpectedly.

Xtreme Mix does not start when start button is pressed.

Fluid valves leaking. Loose or worn packings. Tighten packing nut. If leak continues,

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

Turbine is not supplying enough power to board.

Faulty start switch or wire harness. Check start switch and wiring harness

Faulty stop switch or wiring harness. Check stop switch and wiring harness

Bad I/O port on main board. Replace board. Page 17.

Inspect parts for cured material. Clean or

replace, or use larger hoses and mixer.

1.7-2.4 bar).

Replace bearings. Page 20.

Increase turbine regulator setting to

23-25 psi (172-241 kPa, 1.7-2.4 bar).

Check turbine and electrical control

exhaust air for restrictions.

Replace turbine bearings. Page 20.

continuity; switch is normally open circuit.

See Electrical Schematic, page 28.

continuity; stop switch is normally closed

circuit. See Electrical Schematic, page

28.

replace packings. Page 24.

309518P 13

Troubleshooting

Problem Cause Solution

Flow rate too low. Inadequate air supply. Use larger CFM compressor.

Air pressure to pumps too low. Increase pressure. Fluid A or B filters plugged. Clean filters. See pump manual. Spray tip too small. Relieve pressure. Install larger tip. Follow

gun manual instructions.

Mixer or hoses partially plugged or too restrictive.

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

Pump stops after 12 cycles.

Xtreme Mix makes chirping noise every 60 seconds.

Knob is set to

independently.

Knob is set to

independently.

Run pump A or B

Material too heavy to siphon or gravity feed.

Turn knob to spray

if spraying mate-

rial.

Turn knob to spray

if spraying mate-

rial.

Change material feed/supply method.

14 309518P

Alarms

• An alarm condition will shutdown the equipment.

• A chirping sound every 60 seconds indicates

* Indicates error where audible alarm sounds once briefly.

** Indicates error where audible alarm sound pulses.

the unit is set for recirculation mode.

Code Alarm Active Problem Cause

Startup Errors

01 Sensor Error A* Always No signal from pump A sensor. Loose cable, failed sensor or cable.

Page 27.

02 Sensor Error B* Always No signal from pump B sensor. Loose cable, failed sensor or cable.

Page 27.

03 Controller Error* Always Loss of communication between main

and display boards.

Operating Errors

04 Pump Runaway A** Spray 05 Pump Runaway B**

06 Pump Error A** Spray 07 Pump Error B**

08 Sensor Code Error Always Software boot, sensor values reverted to

09 Metering Error A** Spray A dose too great. Metering valve A leak. Page 24.

Te st

Batch

Te st

Batch

Pump running too fast.

This alarm is not active when pumps are run independently.

Pump does not stall after top change over.

Pump cavitating excessively.

default.

Loose cable, failed board. Page 17.

Empty fluid reservoir(s).

Clogged fluid filter.

Hose rupture after mix manifold.

Sampling valve open too far.

Excessive cavitation. Foot valve leak.

Air in lines caused by loose fitting or use of agitator.

Empty fluid reservoir(s). Sensor value data corrupt; board

needs replacement and /or recalibration. Page 17-19.

Empty B fluid reservoir.

10 Metering Error B** Spray B dose too great. Metering valve B leak. Page 24.

Empty A fluid reservoir. 11 Sensor Reading Low A* Always Pump stroke travels beyond sensor 12 Sensor Reading Low B*

13 Sensor Reading High A* Always Pump stroke travels beyond sensor 14 Sensor Reading High B*

range at bottom change over.

range at top change over.

Sensor or bracket loose. Page 27.

Sensor magnet dirty.

Sensor or bracket loose. Page 27.

Sensor magnet dirty.

Testing Error

15 Piston packing/ball A* Test Pump does not completely stall in up 16 Piston packing/ball B* 17 Inlet Ball A* Test Pump does not completely stall in down18 Inlet Ball B* 19 Metering Valve A* Test Pump does not completely stall in both 20 Metering Valve B*

309518P 15

stroke.

up and down strokes.

Piston packing or ball check failure.

Foot valve ball check failure.

Throat packing or metering valve fail-

ure. Page 24.

Repair

Follow Shutdown procedure, page 9, if service time may exceed pot life time, before servicing fluid components, and before transporting equipment to a service area.

WARNING

Read warnings, page 5.

Replacing Air Filter Element

There are 2 air filters on the unit: the 5 micron air manifold filter (518) and 40 micron pump air filter (8). Check filters daily and replace element as needed.

WARNING

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

3. Unscrew filter bowl. F

IG. 4

4. Remove and replace element.

5. Screw filter bowl on securely.

IG. 4.

Pump Air Filter

2. Unscrew filter bowl. FIG. 5.

Both Filters

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

Air Manifold Filter

2. Remove air manifold cover (42). FIG. 3.

IG. 3

IG. 5

3. Unscrew plate.

4. Remove and replace element. F

IG. 6

5. Reassemble.

IG. 6.

16 309518P

User Interface

Repair

Removing Cover

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

2. Remove air manifold cover (42). F

3. Remove four nuts (32) and open user interface cover (4). F

IG. 7

IG. 7–FIG. 8.

315

IG. 3, page 16.

301

406 416

C D

IG. 9

3. Install new chip (beveled corner down).

4. Reassemble.

5. Recalibrate main circuit board. See page 19.

Replacing Main Circuit Board

CAUTION

To avoid damaging circuit board, wear a grounding strap.

1. Remove User Interface cover. See above.

2. Disconnect all wire connectors from board (301). F

IG. 10.

IG. 8

4. To completely remove cover (4), disconnect ground wire (315), wires (416 and 406) from main board (301). See F

IG. 8 and Electrical Schematic, page

28.

Software Upgrades

CAUTION

To avoid damaging circuit board, wear a grounding strap.

1. Remove User Interface cover. See above.

2. Use a chip remover (D) to remove software chip (C). F

IG. 9.

3. Remove four screws (302) and replace board (301).

4. Reassemble. Refer to Electrical Schematic, page

28.

5. Recalibrate main circuit board. See page 19.

10 9 8 7 6 5 4 3

301

302

IG. 10

309518P 17

Repair

Replacing Display Circuit Board

CAUTION

To avoid damaging circuit board, wear a grounding strap.

411

410

1. Remove User Interface cover. See page 17.

2. Disconnect wires from display board (410). F

IG. 11.

3. Remove two screws (411).

4. Remove setscrew (B) from knob (405) and remove knob assembly.

5. Remove and replace display board (410).

6. Reassemble. Refer to Electrical Schematic, page

28.

Ref. 416

416

406

Back View

405

Align knob to allow for turning to all 6 settings.

FIG. 11

18 309518P

Recalibrate Circuit Board

Follow this procedure whenever the main circuit board, software, or sensor is replaced, or when Alarm 8 occurs (refer to page 15).

1. Note calibration value on pump A sensor. Refer to F

IG. 23, page 27.

2. Open main air valve to start unit.

Repair

3. Turn knob to pump A . F

IG. 12. Hold down

Stop button about 5 seconds. The default calibration (number between 85000 - 95000) displays.

4. Use key (X) to change default to calibration value noted previously.

5. Note calibration value on pump B sensor.

6. Turn knob to pump B . Hold down Stop

button about 5 seconds. The default calibration displays.

7. Use key (X) to change default to calibration value noted previously.

PSI Bar MPa

A or B

IG. 12

If data download is used, set date and time after calibrating, using Xtreme Mix software.

309518P 19

Repair

Pneumatic Control

Alternator Repair

Turbine Alternator Repair Kit 223688 is available to replace turbine bearings.

1. Remove User Interface cover. See page 17.

306r

10 9 8 7 6 5 4 3

301

304

IG. 13

2. Disconnect power supply wires (P). F

IG. 13.

310

3. Disconnect two air lines (310) from alternator (304). F

IG. 14.

4. Remove top nut (305) and loosen bottom nut. Slide alternator up and off bottom nut.

IG. 14

305

304

304d

310

304a

304d

304e

5. Remove four screws (304d) to separate alternator housings. F

IG. 15.

6. Disconnect turbine (304e) from board (A). Follow

Torque to 20 in-lbs (2 N•m)

IG. 15

instructions in turbine kit manual 308034 to remove and repair turbine.

7. Replace gasket (304a) if damaged. Place between housings before securing with screws (304d).

8. Reassemble. Refer to Electrical Schematic, page

28.

• Lightly lubricate turbine o-ring before installing turbine in housing.

• Connect alternator red wire to + side and black wire to – side of main circuit board.

• Connect turbine to 3-pin connector on main circuit board.

20 309518P

Repair

Replacing Solenoids

Follow this procedure to replace a single solenoid.

1. Remove User Interface cover. See page 17.

2. Disconnect two solenoid wires (V) from main board. F

IG. 16.

3. Remove two screws (S).

4. Remove and replace solenoid (306b).

From left to right, solenoid functions are as follows:

• Metering valve A

• Metering valve B

• Pump A

• Pump B

5. Reassemble. Solenoid wires are polarized (red +, black –). Refer to Electrical Schematic, page 28.

Replacing Alternator Regulator

1. Remove User Interface cover. See page 17.

3. Disconnect supply and exhaust air lines (310).

4. Disconnect solenoid wires 12 position Phoenix connector (306r) from main board. F

IG. 13, page 20.

5. Remove solenoid module (306) with regulator (306e). F

IG. 16.

6. Unscrew and replace regulator (306e).

7. Reassemble. Refer to Electrical Schematic, page

28.

Make sure gaskets (306j, 306k) are in place when reinstalling solenoid module.

8. Set regulator to 24 psi (160 kPa, 1.6 bar).

Replacing Alarm

1. Remove User Interface cover. See page 17.

2. Disconnect alarm wires from main board.

3. Unscrew alarm (313) and replace. F

IG. 16.

2. Remove two screws (309). F

306k

306b

306e

306j

IG. 16.

306

4. Reassemble. Refer to Electrical Schematic, page

28.

309

310

313

Set regulator pressure to 24 psi (160 kPa, 16 bar)

IG. 16

309518P 21

Repair

Pump Air Manifold

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

2. Pull off regulator knob (R). F

3. Remove two screws (44).

4. Disconnect two hoses (515) from pump motors.

5. Replace parts as needed. See page 40.

6. Reassemble.

IG. 17.

IG. 17

515

22 309518P

Sampling Valve

WARNING

Read warnings, page 5.

1. Follow Pressure Relief Procedure, page 7.

2. Unscrew sampling valve assembly (83) from metering valve (601).

3. Unscrew seat (83c).

4. Remove o-rings (83f), ball (83d), seat (83g), and gasket (83h).

5. Replace parts as needed and reassemble.

Repair

83c

83h

83g

83d

83f

83b

83e

606 (side A)

611 (side B)

83a

Lubricate.

Apply anaerobic sealant. Torque to 130-140 in-lbs (15-16 N•m)

IG. 18

601

607

309518P 23

Repair

Metering Valve/Manifold Assembly

WARNING

Read warnings, page 5.

Removing Assembly

1. Follow Pressure Relief Procedure, page 7.

2. Disconnect top and bottom black air tubes.

3. Unscrew fluid tube.

4. Remove nuts (26), screws (27, 48) and lockwashers (25). F

IG. 19.

5. Remove metering valve manifold (6).

Removing Metering Valve

1. Remove Metering Valve/Manifold Assembly.

Servicing Metering Valve

Follow this procedure to replace packings. Reference numbers with * are included in repair kit 234098. Reference numbers with † are included in repair kit 234131.

1. Remove metering valve.

2. Remove two locknuts (636). F

3. Remove packing nut (627).

4. Remove inlet housing (628).

5. Unscrew needle (630*) from piston rod (625).

6. Remove packings (637*, 638, 639*). Inspect needle (630*) and replace if worn.

If piston valve packings need replacement:

7. Unscrew cap (622).

8. Unscrew locknut (631).

9. Remove piston (623) and replace o-rings (632*†, 633*†, 634*†).

IG. 20.

2. Unscrew metering valve (601) from shutoff valve (606 or 611).

3. If necessary, remove and repair or replace shutoff valve (606 or 611). See manual 306861.

48*

Manifold

245833

FIG. 19

601

606 (side A) 611 (side B)

607a

10. Replace piston rod o-ring (643*†) if damaged.

11. Reassemble.

Manifold 248843

24 309518P

Repair

621

622

*† 634

† 632

631

623

*† 633

† 635

624

*† 643

*† 638

629

*† 637

627

626

639*†

628

636

630†

645*† 644† 645*†

646

625

1. Apply pipe sealant to non-swiveling pipe threads.

2. Apply lubricant to threads, o-rings, and seals.

Apply medium anaerobic adhesive. Thread to bottom.

Torque to 5-7 ft/lbs (7-9 N•m).

Torque to 30-40 ft/lbs (41-54 N•m).

Tighten packing nut 1/4 turn after nut bottoms out; 145-155 in/lbs (16-18 N•m). Check packing nut tightness about once a month. Keep packing nut filled with TSL.

Lubricate and press piston evenly into cylinder.

FIG. 20

621

647

Clean needle (630) and packing cavity before reinstalling packings (637*, 638, 639*). Lubricate packings and install with lips facing up toward packing nut (627) in order shown.

Whenever the seat housing (646) is removed, replace the o-rings (645).

Inspect reversible seat for damage. If one side is worn, reverse seat.

309518P 25

Repair

Servicing Fluid Manifold 245833

Follow this procedure to replace packings. Reference numbers with * are included in repair kit 234100.

1. Remove metering valve. See page 24.

2. Unscrew plug (661).

3. Remove and replace o-rings (662*, 663*, 665*), seat (664*), ball (666*), and spring (667*).

CAUTION

Do not assemble static mixer directly to fluid manifold. Install static mixer after first 50 ft. (15 m) of hose to ensure material is completely mixed. Spraying unmixed material could necessitate rework of part sprayed. See Setup in Xtreme Mix Operation manual.

Servicing Fluid Manifold 248843

4. Reassemble.

661

*662

*663

*665

*664

*665

*666

*667

Manifold 245833

1. Apply pipe sealant to non-swiveling pipe threads.

2. Apply lubricant to threads, o-rings, and seals.

674

675

There are no serviceable parts on manifold 248843.

676

669

665

670

668

FIG. 21

26 309518P

Repair

Sensor

CAUTION

To avoid damaging board, wear a grounding strap.

Reference numbers with * are included in repair kit

246345. Reference numbers with † are included in repair kit 246344.

1. Close main air shutoff valve on air supply line and unit. F

IG. 22.

PLURAL COMPONENT PROPORTIONER

VALVEBAVALVE

IG.

SETUP KEY

DATA PORT

IG. 22

PUMP AIR

PRESSURE

PSI Bar MPa

SUPPLY AIR PRESSURE

PSI Bar MPa

2. Unscrew sensor cap (701†) from nut (712†). F

23.

3. Disconnect cable (705*).

†712

†714

†707

†706

†708

704†

703†

701†

720†

710*

709*

702*

705*

719*

713*

721*

711*

4. Unscrew fitting (713*), locknut (719*), and cover (702*).

5. Disconnect sensor cable (Y) from board (703†).

6. Remove and replace parts as needed.

7. Reassemble and mount sensor. Refer to Electrical Schematic, page 28.

Mount sensor as close to magnet as possible without touching it.

8. Recalibrate main circuit board. See page 19.

Displacement Pump

WARNING

Read warnings, page 5.

Torque to 60 in-lbs (7 N•m).

Plug connector into connector on board (703).

Calibration value location.

Before assembling cover (702*) to cap (701

†), assemble cable

(705*) through fitting (713*) and cover (702*), and plug cable into connector on board (703

†) and to ground lug.

FIG. 23

2. Disconnect 90° swivel (30) from pump lower. Refer to page 32.

3. Remove pump lower and service as instructed in pump manual 311762.

1. Follow Pressure Relief Procedure, page 7.

309518P 27

Electrical Schematic



*   



        

  

                 

 

      



    

Jumper (15V)

*

*

*

*

Main Circuit Board 245705

6$#

  

           

         



      

      

     

#/-

2 ",

Solenoids

",7

",2

",'

7 ",7

",2

' ",'



  



  

Metering Valve A Metering Valve B Pump A Pump B

Metering Valves

Air Motors

     

Sensor 243678

2 ", 2 ",

Case Gnd Clip

2 7 ",

     

*

Key:

BL Black BR Brown BL-GBlack with green BL-RBlack with red

28 309518P

BL-WBlack with white G Green GNDGround R Red

S Shield W White

Electrical Schematic

301

Power Supply Barrier Board

Alarm 15A849

Alarm + Alarm COM

2 7 ",

304

Power Supply

Air Input

Front Panel

COM Port RS232 Connector

  

Start



Comport Pin Front View



48 28 '.$





'.$

Start/Stop Switch 15A851

Light



Stop



'.$

Key Switch 15A852

Display Board 245706

     

*     

*   











  

", 2 '

 











 

Key Switch momentary

309518P 29

Pneumatic Schematic

Manifold

1/2 in. x 24 in. long

Air

Exhaust

Air Supply

12 VDC

Solenoid

A Metering

Position 1

Val ve

B Metering

A Pilot

To P u mp

3-way valve

B Pilot

To P u mp

3-way valve

304

Turbine / Power Supply

306t

12 VDC

Solenoid

Position 2

12 VDC

Solenoid

Position 3

12 VDC

Solenoid

Position 4

26 psi (79 kPa, 1.8 bar)

Relief Valve

To Manifold

3/8 in. tube

524

B Pilot

Pump A Pilot

Pump

306e

Alternator Air

Regulator

501

90/110 psi 0.6/0.8

MPa, 6.2/8 bar)

Relief Valve

110 psi

(0.8 MPa,

8 bar) Relief

King Motor B

King Motor A

Gauge

Val ve

518

3/4 in. Ball Valve

3/8 in. Air Reg.

Auto Drain

5 micron

Gauge

100 psi (0.7

MPa, 7 bar)

bleed type

503

Air Regulator

3/4 in. Air Filter

Auto Drain

20 micron

FIG. 24

30 309518P

Pneumatic/Sensor Connections

Key:

A Pump A Air B Pump B Air C Pump A Pilot Air D Pump B Pilot Air E Air Supply F Metering Valve A - CLOSE G Metering Valve A - OPEN H Metering Valve B- CLOSE J Metering Valve B- OPEN K Sensor A Cable L Sensor B Cable

FIG. 25

309518P 31

Parts

Xtreme Mix Proportioner

Parts shown here and page 34 and 36.

DETAIL D

Ref. 6

(side B) 45 (side A) 46

Ref. 3, 4, 5

Parts for Model 248842

Ref. 6

(side B) 45 (side A) 46

TI2321A

Ref. 62

See DETAIL C

*26

*25 *87

See DETAIL B

See DETAIL A & D

*87

17,29,37,

38,40

Ref. 6

24 25

11,12,13

Ref. 71

97**

97b

97c

90**

97d

97a

97e

32 309518P

TI2321B

*59

*60

*33

*30

6864

(blue) *16 (green) *78

TI2317A

Xtreme Mix Proportioner

Part Number Table

Parts

Refer to page 3 for additional model information.

Approved for Non-hazardous Location

Xtreme

Mix Pump (2)

233863 249274 (45:1) 245824 XTR704 H53850 15B729 113498 15A914 15A915 233864 249275 (56:1) 245824 XTR704 H53850 15B729 113498 15A914 15A915 233865 249276 (68:1) 245824 XTR704 H73850 15B729 113498 15A914 15A915 233866 249277 (80:1) 245824 XTR704 H73850 15B729 116643 15A914 15A915 233867 249278 (45:1) 245824 XTR704 H53850 15B729 113498 15A914 15A915 233868 249279 (56:1) 245824 XTR704 H53850 15B729 113498 15A914 15A915 233869 249280 (68:1) 245824 XTR704 H73850 15B729 113498 15A914 15A915 233870 249281 (80:1) 245824 XTR704 H73850 15B729 116643 15A914 15A915 248842 249276 (68:1) 248843 none none none 108124 15A914 15A915

Metering Valve (6)

Gun

(15)

Hose

(20)

Coupling

(56)

Relief

Valve (79)

Tube

(45)

Tube

(46)

309518P 33

Parts

Ref. No. Part No. Description Qty.

1 245997 CART 1

see table,

page 33

PUMP; see manual 311762 for parts

3 245803 PNEUMATIC CONTROL; parts

page 37 4 245804 USER INTERFACE; parts page 39 1 5 245802 PUMP AIR MANIFOLD; parts page 401

6 245824

see table, page 33

248843

see table, page 33

METERING VALVE MANIFOLD;

parts page 41

METERING VALVE MANIFOLD;

parts page 41; used on model

248842 only 7 245825 SENSOR; parts page 44 2 8* 117628 AIR FILTER; 3/4 npt; 40 micron 1 9 244524 GROUND WIRE, with clamp; not

shown 10* 551390 BEAKER 2 11 15A847 MAGNET HOLDER 2 12‡ 15A814 MAGNET; 2.7 ft. (0.8 m) 2 13 104092 SCREW; 10-24 UNC 4

see table,

15*

page 33

SPRAY GUN, see manual 312145 1

16* 234017 FLUID RESERVOIR, blue 2 17 C19041 WASHER 1 18* 214954 AIR HOSE; 3/4 x 1/2 npt; 2.75 ft.

(0.84 m); not shown 20* H73850

see table, page 33

H53850

see table, page 33

HOSE, fluid; nylon; 3/8 in. (10 mm)

ID; 3/8 npsm(fbe); 50 ft (15.2 m)

long

HOSE, fluid; nylon; 3/8 in. (10 mm)

ID; 3/8 npsm(fbe); 50 ft (15.2 m)

long 21* 511352 STATIC MIXER 1 22* 150287 COUPLING; 3/8 npt 1 24 100004 SCREW; 3/8 UNC 8 25 100133 LOCKWASHER †15 26 100131 NUT; 3/8-16 UNC †15 27* 115348 SCREW; 3/8-16 UNC x 2.75 in. 2 28* 15A776 PLATE 1 29 207675 AIR MANIFOLD 1 30* 112580 SWIVEL, 90°; 1.25 npsm 2 31 100016 LOCKWASHER 4 32 100015 NUT; 1/4-20 UNC 4 33* 117366 SHUTOFF VALVE, 3-way; 1/2 npt 2 34‡ C12508 TUBE, nylon; 3/8 in. (9.5 mm) OD;

★

1 ft. (0.3 m); not shown 35‡ 054753 TUBE, nylon, black; 0.156 in.

★

(4 mm) OD; 6 ft. (1.8 m); not shown 36 15A845 LABEL, air supply pressure 1 37 100139 PLUG; 1/8 nptf 1

Ref. No. Part No. Description Qty.

38 100721 PLUG; 1/4 nptf 1 39 101566 LOCKNUT, not shown 1

40‡ PLUG 1 42 15B281 COVER 1

43 112774 SCREW, 1/4-20 6 44 103196 SCREW, #8-32 x 0.44 in. 6

see table,

page 33 see table,

page 33

TUBE, pump B 1

TUBE, pump A 1

47 117344 FITTING; 1/2 npt(m) x 5/8 in.

48 100560 SCREW; 3/8-16 UNC x 4.75 in. 1 or

(16 mm) tube

49 158683 ELBOW, 90°; 1/2 npt 2

15B729

56*

see table, page 33

COUPLING 1

57* H72506 HOSE, fluid; nylon; 1/4 in. (6.3 mm)

ID; 1/4 npsm(fbe); 6 ft (1.8 m)

58* 243832 KIT, siphon hose; 1/2 npsm(f) x 1/2

npt; not shown 59* 117525 ELBOW, 90°; 1/2 npt 1 60* 108143 STRAINER; 16 mesh 1 61* C19660 FITTING; 1-1/4 x 1/2 npt; not

shown 62 246127 CART HANDLE 1

63 15B161 AXLE 1 64 113362 WHEEL 2

65 113436 RETAINING RING 3 66 15B755 SPACER 2 67 114552 CAP 1

68 154628 WASHER 3 70 054139 TUBE, nylon; 1.5 ft. (0.46 m);

0.5 in. OD; not shown 72 101242 RETAINING RING 2 73 113807 WHEEL 2 74 15A912 AXLE, vertical 1 75 15A913 AXLE, horizontal 1 76 191824 WASHER 4 77 15A892 BEARING, brass 2 78* 234097 FLUID RESERVOIR; green 1 79 113498

see table, page 33

116643

see table, page 33

108124

see table, page 33

SAFETY RELIEF VALVE; 110 psi (0.8 MPa, 8 bar)

SAFETY RELIEF VALVE; 90 psi (0.6 MPa, 6.2 bar)

SAFETY RELIEF VALVE; 75 psi (0.5 MPa, 5.2 bar)

80 124450 CLAMP 2 81 C20490 FITTING 2

2**

★

34 309518P

Parts

Ref. No. Part No. Description Qty.

83 245143 SAMPLING VALVE; parts page 41 2 84* 116746 FITTING; 1/8 npt x 1/4 in. (6.4 mm)

tube; see page 41

85* 116750 TUBE, nylon; 5 in. (12.7 cm); parts

page 41 86 193185 LABEL, warning 3 87* 15C567 BRACKET, hopper 2 88* 100132 WASHER, flat; not shown 4 90** 116401 ELBOW, 90° 2 97** 249024 STRAINER KIT; 500 psi (3.4 MPa,

34 bar) maximum working pres-

sure; includes items 97a-97e 97a C20490 • NIPPLE, hex; 1 in. npt 2

Hose and Gun

Ref. No. Part No. Description Qty.

97b 160022 • UNION; 1 in. npt(m) x 1 in.

npsm(m) 97c 110878 • STRAINER; 1 in. 1 97d 118464 • BALL VALVE; 1 in. 1

97e 202965 • UNION; 1 in. npt(m) x 3/4

npsm(f) 98 100451 COUPLING 1 99 115671 FITTING, (m) 1/8 npt 1 100 054123 TUBE, draining 2ft.

* Not included with Model 248842. ** Included with Model 248842 only.

‡ Not available for order from Graco.

★ Order length needed from distributor.

*15

*56

*21

*22

20*

*57

309518P 35

Parts

DETAIL B

83, 84, 85

48*

99 98

100

10*

TI2316A

Parts for Model 248842

28*

DETAIL C

7777 74

DETAIL A

36 309518P

Pneumatic Control 245803

Item 3, page 33

Parts

302 301

313

TO SOLENOIDS

FROM TURBINE POWER

306r

Ref. 304

306

303

320

321

311

315

304

312 317

307

TO PUMP POSITION SENSORS

309518P 37

314

MOTOR A

MOTOR B

306

B PUMP

A PUMP

REF 310

316

313

304

305

310

309

TI2303A

Parts

Pneumatic Control 245803

Ref. No. Part No. Description Qty.

301 245705 CIRCUIT BOARD 1 301a 15C318 FUSE, circuit board 1 302‡ SCREW; 8-32 UNC 4 303‡ COVER 1 304** 245854 ALTERNATOR MODULE; includes

items 304a-304e 304a 193154 • GASKET 1 304b 15A853 • WIRE HARNESS 1 304c 111225 • TUBE FITTING; 90° 2 304d 114380 • SCREW; M5 x 25 4 304e 249254 • TURBINE ALTERNATOR 1 305‡ LOCKNUT; 8-32 UNC 2 306‡ SOLENOID MODULE, IS; includes

items 306a-306t 306a 15A822 • MANIFOLD 1 306b 117356 • VALVE, 12 VDC, IS 4 306c 114263 • FITTING; 1/8 npt x 5/32 in.

(4 mm) tube 306d‡ • NIPPLE; 1/4 npt 1 306e 115243 • AIR REGULATOR; 1/4 npt 1 306f 115841 • ELBOW, swivel; 1/4 npt x 3/8 in.

(9.5 mm) tube 306g 160701 • ELBOW, street; 1/8 npt(m x f) 1 306h 108190 • GAUGE, 1 306j‡ • GASKET, neoprene 1 306k‡ • GASKET, neoprene 1 306n‡ • PLUG, pipe; 1/8-27 ptf 5 306p 114128 • ELBOW; 1/4 npt x 1/2 in. (13

mm) tube 306q

† 112512 • WIRE FERRULE, orange (not

shown) 306r 117369 • CONNECTOR, 12 position 1 306s 150278 • ADAPTER, 1/4 x 1/8 npt 1 306t 117480 • SAFETY RELIEF VALVE, 26 psi

(179 kPa, 1.8 bar) 307 15A800 GASKET, neoprene 1 309‡ SCREW; M5 x 10 2 310 C12508 TUBE, poly-flo; 3/8 in. OD; 1 ft.

★

(3 m) 311‡ NUT, KEPS; #10-24 1 312 104029 GROUNDING STUD 1 313 15A849 WIRE HARNESS, alarm 1 314 117442 CONNECTOR, 18 position 1

Ref. No. Part No. Description Qty.

315 15B090 GROUNDING WIRE, door 1 316 15B056 LABEL, air connections 1 317 111307 LOCKWASHER 1 320 118132 LOCKWASHER, terminal 1 321 118129 SPACER, 8-32 UNC x 5 in. (127

IS = intrinsically safe ** Alternator bearing repair kit 223688 available.

mm)

‡ Not available for order from Graco.

★ Order length needed from distributor.

38 309518P

User Interface 245804

Item 4, page 33

Parts

Ref. 407

Ref. 403 Ref. 416

416

Back View

412

418

414, 415

Ref. 406

413

406

407

405,419

15A804

401

404

Ref. 407

410

Ref. 405

411

409

403

Ref. No. Part No. Description Qty.

401‡ COVER 1 403 15A851 WIRE HARNESS, start/stop 1 404 15A801 GASKET 1 405 15C335 KNOB 1 406 15A850 WIRE HARNESS, data port 1 407 15A852 WIRE HARNESS, key switch 1 409* LABEL, alarm code 1 410 245706 CIRCUIT BOARD 1 411‡ SCREW; 4-40 2 412 15A856 DISPLAY PANEL 1 413‡ 514619 NUT; 4-40 4

15A806

Ref. 403

TI2307A, TI2308A

Ref. No. Part No. Description Qty.

414‡ MOUNT 3 415‡ 102478 STRAP 3 416 15A854 WIRE HARNESS, display 1 418‡ WASHER 4 419 107232 SET SCREW 1

Not available for order from Graco.

‡

* Alarm Code Labels

Item 409, English provided. To order other languages:

Part No. Languages

15B843 Chinese, Finnish, Portuguese, Greek, Swedish, Italian 15B844 English, Spanish, French, German, Korean, Japanese

309518P 39

Parts

Pump Air Manifold 245802

Item 5, page 33

502

504 505

503

508

521

503

525

513

501 523 522

513

504 506

507

527

524

510 511

514

512 526

517

518

528

519

520

516

515

TI2295A

Ref. No. Part No. Description Qty.

507 117332 REGULATOR 1 508 100840 ELBOW; 1/4 npt 1 510 15A819 MANIFOLD BLOCK 1 511 160032 NIPPLE; 3/4 npt 1 512 117346 SHUTOFF VALVE, vented 1 513 117364 O-RING, nitrile 3 514 108849 SCREW; 1/4-20 UNC 2 515 15B554 HOSE; 3/4 npt; 4 ft. (1.2 m) 2 516 100549 ELBOW, 90°; 3/4 npt 2 517 165198 NIPPLE; 1/4 x 3/8 npt 1 518 119644 FILTER; 3/8 npt; 5 micron 1 519 114316 ELBOW, swivel; 3/8 npt 1 520 114151 ELBOW, swivel; 1/8 npt x 5/32 in.

(4 mm) tube 521 100721 PLUG; 1/4-18 nptf 2 522 512912 MUFFLER; 1/2 npt 2 523 100896 BUSHING; 3/4 x 1/2 npt 2 524 113498 SAFETY RELIEF VALVE; 110 psi

(0.8 MPa, 8 bar) 525 117443 STANDOFF, aluminum, 8-32 UNC 2 526 240900 HOSE; 3/4 npt; 2.5 ft. (0.76 m) 1 527 158962 ELBOW, 1/8 (m) x 1/4 (f) 1 528 113911 GAUGE, 1/8, air 1

100 psi (0.7 MPa, 7 bar) setting.

Ref. No. Part No. Description Qty.

501 C59752 VALVE, 3-way 2 502 108307 ELBOW; 3/4 npt 2 503 101689 PRESSURE GAUGE 2 504 112166 SCREW; 1/4-20 UNC 4 505 15A820 MANIFOLD 1 506 15A821 PLATE, direction 1

40 309518P

Metering Valve Manifold 245824

Item 6, page 34

Ref. No. Part No. Description Qty.

601 245846 METERING VALVE; parts page 42 2 606 245861 SHUTOFF VALVE; see manual

306861 607a 245833 FLUID MANIFOLD; parts page 43 1 611 245860 SHUTOFF VALVE; see manual

306861

Metering Valve Manifold 248843

Item 6, page 34

Ref. No. Part No. Description Qty.

601 245846 METERING VALVE; parts page 42 2 606 245861 SHUTOFF VALVE; see manual

306861 607b 249406 FLUID MANIFOLD, kit; see right 1 611 245860 SHUTOFF VALVE; see manual

306861

Sampling Valve 245143

Item 83, page 35

Ref. No. Part No. Description Qty.

83a 245110 KNOB 1 83b 197681 HOUSING 1 83c 197332 SEAT 1 83d 107536 BALL, carbide 1 83e 110082 RETAINING RING 1 83f 111457 O-RING, PTFE 2 83g 183548 SEAT 1 83h 187060 GASKET 1

Parts

601

83g

83h

615

83c

616

614

606 (side A) 611 (side B)

612 613

607a

TI2298A

83d

83f

83b

83e

83a

*84

*85

617

610

618

607b

See page 35 for part numbers and descriptions.

Repair Kit 249406

Ref. No. Part No. Description Qty.

610 15E725 FLUID MANIFOLD 1 612 116343 GROUND SCREW 2 613 111307 LOCK WASHER 2 614 101754 PLUG, pipe 2 615 117502 REDUCER; #5 x #8 JIC 1 616 117556 NIPPLE; #8 JIC x 1/2 npt 1 617 117557 NIPPLE; #10 JIC x1/2 npt 1 618 117677 REDUCER, #6 x #10 JIC 1

309518P 41

Parts

Metering Valve 245846

Item 601, page 41

621

622

† 634

† 632

631

623

*† 633

† 635

624

*† 643

*†638

*† 637

▲ 629

627

639*†

626

628

636

630†

645*†

644†

645*†

646

625

Ref. No. Part No. Description Qty.

621 598140 ELBOW, 1/8 npt(m) x 5/32 in.

(4 mm) tube 622‡ 15A840 VALVE CAP 1 623‡ 15A841 PISTON 1 624‡ 15A839 CYLINDER 1 625 15B545 PISTON ROD 1 626 15A834 TIE ROD 2 627 15A835 PACKING NUT 1 628 15A833 INLET HOUSING 1 629

▲ 180233 WARNING LABEL 1

630

† 245850 FLUID NEEDLE 1

631 111040 LOCKNUT, nylon; 5/16 UNC-3B 1 632*

† 117336 O-RING, nitrile 1

633*

† 117370 O-RING, nitrile 1

634*

† 117337 O-RING, nitrile 1

† 109141 SPRING 1

635 636 102040 LOCKNUT; 1/4 UNC 2

621

Ref. No. Part No. Description Qty.

† 117334 V-PACKING, UHMWPE 6

637*

638*

† 189901 GLAND, male 1 † 117335 V-PACKING, leather 5

639* 643*

† 111959 O-RING, buna-n 1

644

† 15A830 SEAT 1

† 15T260 O-RING, fluoroelastomer 2

645* 646 15A832 SEAT HOUSING 1 647 102637 SCREW; 3/8 UNC-2A 4

* Parts included in kit 234098. † Parts included in kit 234131.

‡ Not available for order from Graco.

▲ Replacement Warning labels available at no cost.

647

TI2299A

42 309518P

Fluid Manifold 245833

Item 607a, page 41

661

*662

*663

*665

*664

*665

*666

*667

674

675

668

Parts

676

669

665

670

671

Ref. No. Part No. Description Qty.

661 15A823 PLUG 2 662* 107098 O-RING, PTFE 2 663* 107313 O-RING, PTFE 2 664* SEAT 2 665* 103341 O-RING, PTFE 5 666* BALL, metallic 2 667* 117333 SPRING 2 668 PLUG; 3/8 npt 4 669 15A825 PIPE, outlet 1 670 192977 PIPE, center 1 671‡ HOUSING 1 674 111307 LOCKWASHER 2 675 116343 GROUND SCREW,; M5 x 0.8 2 676 159239 NIPPLE; 3/8 x 1/2 npt 1

* Parts included in kit 234100.

‡ Not available for order from Graco.

TI2304A

309518P 43

Parts

Sensor 245825

Item 7, page 33

715

†714

716†

712†

704†

703†

720†

710*

†701

†707

†706

†708

Ref. No. Part No. Description Qty.

701† 196280 CAP 1 702* 15A818 COVER 1 703† 243500 BOARD 1 704† 115925 SPACER 2 705* 117331 CABLE 1 706† 115917 SENSOR 1 707† 110004 O-RING, PTFE 1 708† 196289 CAP 1 709* 116024 TAB TERMINAL 1 710* 101855 SCREW; 4-24 UNC 1 711* 112546 SCREW; 4-40 taptite 2 712† 15A817 NUT; 1/8 npt 1

709*

702*

705*

719*

713*

721*

711*

TI2301A

Ref. No. Part No. Description Qty.

713* 117569 FITTING; 3/8 npt x 5/16 in. conduit 2 714† 154741 O-RING, buna-n 1 715 245831 BRACKET 1 716† 104765 PLUG; 18-27 ptf 1 719* 117586 LOCKNUT; 3/8-18 npt 2 720† C20272 O-RING; fluoroelastomer 1 721* 117582 CONDUIT, 5 ft. (1.5 m); not shown ★

* Parts included in kit 246345.

† Parts included in kit 246344.

★ Order length needed from distributor.

Calibration label.

44 309518P

Technical Data

Mix ratio range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0:1-10:1 (in 0.1 increments)

Ratio tolerance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . +/- 5%

Flow rates

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

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

Fluid viscosity range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-20,000 cps (heavier viscosities can be mixed with use

of optional heaters, heated hoses, and hardware)

Fluid filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mesh, (238 micron) standard on pump outlets (Filter

assembly not included on models 248831, 248832, 248833, and 248834)

Air inlet

Model 248842. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

All Other Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model 248842: Fluid inlet . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm union in 1 in. npt(f) ball valve

Maximum fluid working pressure

45:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500 psi (31 MPa, 310 bar)

56:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5600 psi (38.6 MPa, 386 bar)

68:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6800 psi (46.9 MPa, 469 bar)

68:1 Model 248842 only . . . . . . . . . . . . . . . . . . . . . . . 5000 psi (34.5 MPa, 345 bar)

80:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7250 psi (50 MPa, 500 bar)

Air supply pressure range . . . . . . . . . . . . . . . . . . . . . . . . . 50-110 psi (345-800 kPa, 3.5-8 bar)

Model 248842: Maximum fluid feed pressure. . . . . . . . . . 500 psi (3.5 MPa, 35 bar)

Maximum air consumption at 100 psi (0.7 MPa, 7 bar) in cfm (m

45:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 (3.1)

56:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 (3.5)

68:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 (4.4)

80:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 (5.1)

Ambient temperature range

Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-130° F (0-54° C)

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160° F (–1-71° C)

Environmental Conditions Rating . . . . . . . . . . . . . . . . . . . Indoor/outdoor use

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

Wetted parts

Suction tubes (if used) . . . . . . . . . . . . . . . . . . . . . . . . aluminum

Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . carbon steel, alloy steel, 303, 440 & 17-4ph grades stain-

Metering Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . carbon steel, zinc plating, carbide, polyethylene, leather

Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . carbon steel, zinc plating, carbide, 302 stainless steel

Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stainless steel

Spray gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See gun manual

3/4 npt(m) 3/4 npt(f)

/min.)

Altitude up to 4000 meters Maximum relative humidity to 99% up to 54° C Pollution degree (11) Installation category (2)

less steel, zinc and nickel plating, ductile iron, tungsten carbide, PTFE, leather

309518P 45

Technical Data

PC Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-232

Dimensions

Cart model (width x height x diameter) . . . . . . . . . . . 33 in. wide x 64.53 in. high x 44.5 in. deep

(83.8 x 163.9 x 113 cm)

Weight (cart, without hose and gun) . . . . . . . . . . . . . 625 lbs. (285 kg)

* Minimum flow rate is dependent on the material being sprayed and mixing capability. Test your material for spe-

cific flow rate.

46 309518P

Technical Data

309518P 47

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.

Original instructions. This manual contains English. MM 309518

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

www.graco.com

Revised 01/2011

Graco 309518P User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Xtreme Mix Models

Manual Conventions

Related Manuals

Warnings

Pressure Relief Procedure

Proper Lifting of Unit

Grounding

Shutdown

Maintenance

Metering Valve

Pump

Turbine Alternator

Air Filters

Pump Test

Troubleshooting

Alarms

Repair

Replacing Air Filter Element

User Interface

Pneumatic Control

Pump Air Manifold

Sampling Valve

Metering Valve/Manifold Assembly

Sensor

Electrical Schematic

Pneumatic Schematic

Pneumatic/Sensor Connections

Parts

Metering Valve Manifold 245824

Metering Valve Manifold 248843

Sampling Valve 245143

Repair Kit 249406

Technical Data

Graco Standard Warranty

Graco Information