Instructions-Parts
3A0420T
XP Proportioners
Mechanically linked fixed ratio plural-component system used for proportioning, mixing,
and spraying two component coatings. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 11 for maximum working pressure and model
information.
XP70 system shown with hoppers and optional
solvent flush pump and heaters.
EN
r_571100_3A0420A_1a-2
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Two-Component Material Information . 7
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 7
Keep Components A and B Separate . . . . . . . . . 7
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 7
Foam Resins with 245 fa Blowing Agents . . . . . . 7
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 8
A and B Component Designations . . . . . . . . . . . 8
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Over Pressure Protection . . . . . . . . . . . . . . . . . . 9
Initial System Setup . . . . . . . . . . . . . . . . . . . . . . . 10
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cart-Mounted Systems . . . . . . . . . . . . . . . . . . . 11
Bare Proportioning Pump Packages . . . . . . . . . 13
Component Identification . . . . . . . . . . . . . . . . . . . 14
Fluid Control Assembly . . . . . . . . . . . . . . . . . . . 15
Main Air Controls . . . . . . . . . . . . . . . . . . . . . . . 15
45:1 Solvent Flush Pump Kit 262393 (optional) 16
Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 17
Flush Before Using Equipment . . . . . . . . . . . . . 17
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wire Systems with Explosion-Proof Heaters . . . 19
Motor Position . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connect Air Supply . . . . . . . . . . . . . . . . . . . . . . 21
Connect Static Mixers, Gun, and Hoses . . . . . . 21
Connect Fluid Hose Bundles (Remote Mix Manifold
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 22
Prime Empty System . . . . . . . . . . . . . . . . . . . . . . . 23
Prime A and B Fluids . . . . . . . . . . . . . . . . . . . . 23
Prime Solvent Flush Pump . . . . . . . . . . . . . . . . 24
Recirculate Prior to Spraying or Re-Prime After a
Pump Runs Dry . . . . . . . . . . . . . . . . . . . . . 25
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
B Side Mix Manifold Restriction . . . . . . . . . . . . . . 27
Flush Mixed Material . . . . . . . . . . . . . . . . . . . . . . . 28
Flush Mix Manifold, Hose, and Spray Gun . . . . 28
Empty and Flush Entire System
(new system or end of job) . . . . . . . . . . . . . . 29
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
System Verification . . . . . . . . . . . . . . . . . . . . . . . . 31
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Hose Electrical Resistance . . . . . . . . . . . . . . . . 32
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . 32
Recommended Spare Parts . . . . . . . . . . . . . . . 32
Change the Mix Ratio . . . . . . . . . . . . . . . . . . . . 32
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pump Troubleshooting . . . . . . . . . . . . . . . . . . . 34
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 35
Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Mix Manifold Assembly . . . . . . . . . . . . . . . . . . . 38
Fluid Circulation Manifold with Over Pressure Relief
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Optional Solvent Pump . . . . . . . . . . . . . . . . . . . 40
Optional Fluid Heaters . . . . . . . . . . . . . . . . . . . . 41
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cart-Mounted System . . . . . . . . . . . . . . . . . . . . 42
Bare Proportioning Pump Package . . . . . . . . . . 50
Air Controls, 258983 . . . . . . . . . . . . . . . . . . . . . 52
Fluid Circulation Manifold with Over Pressure Relief
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Recommended Spare Parts . . . . . . . . . . . . . . . . . 54
Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . 55
Acceptable For Use in Explosive Atmospheres . 55
Not Approved For Explosive Atmospheres . . . . 56
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Bare Proportioner Mounting Hole Dimensions . 60
Wall Mount Bracket 262812 Dimensions . . . . . . 61
Floor Stand 24M281 Dimensions . . . . . . . . . . . 62
Hydraulic Unit Dimensions . . . . . . . . . . . . . . . . 62
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 64
2 3A0420T
Related Manuals
Manuals are available at www.graco.com. Component
manuals in English:
Manual Description
™
XTR
312145
Pump Package Components
307158
311238
311762
312747
406860
309524
309525 Heated Hose Kit, Instructions-Parts
5 and XTR™ 7 Spray Guns
Instructions-Parts
Viscount
®
II Hydraulic Motor Instruc-
tions-Parts
®
NXT
Air Motor Instructions-Parts
Xtreme
®
Displacement Pumps
Instructions-Parts
Hopper Kits
20 Gallon Double Wall Hopper Kit
Instructions-Parts
7 Gallon Hopper Installation Kit Instructions-Parts
Heating
Viscon
®
HP Heater Instructions-Parts
Related Manuals
313259 Hopper or Hose Heat Circulation Kit
406861
Viscon HP Heater Adapter Kit, Instructions-Parts
Solvent Flush
310863 Feed and Solvent Flush Kits
312794
Merkur
Instructions-Parts
®
Pump Assembly
Accessories and Kits
309852
311486
312769
339361
Polyurethane Circulation and Return
Tube Kits, Instructions-Parts
™
DataTrak
Conversion Kit, Instruc-
tions-Parts
Feed Pump and Agitator Kits
Instructions-Parts
High Pressure Hose and Accessories
Brochure
3A0421 Ratio Check Kit, Instructions-Parts
3A0590
3A2573
Mix Manifold, Quickset Mix Manifold
Instructions-Parts
Gun Splitter Valve with Independent
Flush, Instructions-Parts
406739 Desiccant Kit Instructions-Parts
3A0420T 3
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 symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
WARNINGWARNINGWARNING
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.
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
This equipment must be grounded. 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.
4 3A0420T
Warnings
WARNING
WARNINGWARNINGWARNING
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 spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• 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.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
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 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. For complete information about
your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
• 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.
MOVING PARTS HAZARD
Moving parts can pinch, cut 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 and disconnect all power sources.
3A0420T 5
Warnings
WARNING
WARNINGWARNINGWARNING
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 MSDSs 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 chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
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, hearing loss, inhalation of
toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
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.
6 3A0420T
Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions
Spraying or dispensing 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.
Material Self-ignition
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
material MSDS.
Keep Components A and B
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 pump wetcup or reservoir (if installed)
filled with Graco Throat Seal Liquid (TSL
206995. The lubricant creates a barrier between the
ISO and the atmosphere.
• Use moisture-proof hoses specifically designed for
ISO.
• 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 lubricate threaded parts with TSL or grease
when reassembling.
™
), Part
Separate
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or
damage equipment. To prevent cross-contamination
of the equipment’s wetted parts, never interchange
component A (isocyanate) and component B (resin)
parts.
3A0420T 7
Foam Resins with 245 fa Blowing Agents
Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure, especially
if agitated. To reduce frothing, minimize preheating in a
circulation system.
Important Two-Component Material Information
Changing Materials
• Changing material types used in your system
requires special attention to avoid equipment damage and downtime.
• Always clean the fluid inlet strainers after flushing.
• When changing between epoxies and urethanes or
polyureas, disassemble and clean all fluid components and changes hose sets.
• Check with your material manufacturer for chemical
compatibility.
• Most materials use ISO on the A side, but some use
ISO on the B side.
• Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
A and B Component Designations
Material suppliers and markets refer to plural component materials differently. The table below summarizes the different designations for the components used in various machines.
Market Equipment Designations
Foam and Polyurea, and
Urethane Pour
Epoxy and Urethane
Protective Coatings
Epoxy, Silicone, Ure-
thanes, and other mate-
rials
All Reactors, HFR
®
, Xtreme-
™
and PR
™
and VRM
Hydra-Cat
™
, XM™, and XP
Mix
PR70
Letter
Color
™
,
Component Names
Major or Minor Component
(when not 1:1 mix)
Letter
Color
Component Names
Major or Minor Component
(when not 1:1 mix)
Letter
Color
Component Names
Major or Minor Component
(when not 1:1 mix)
Machine Left
Side
AB
Red Blue
ISO, Hardener,
Catalyst
Low Volume
Side
AB
Blue Green
Resin, Base
High Volume
Side
AB
Red Blue
Polyol, Resin,
Base
High Volume
Side
Machine Right
Side
Polyol, Resin,
Base
High Volume
Side
Hardener, Cata-
lyst
Low Volume
Side
ISO, Hardener,
Catalyst
Low Volume
Side
8 3A0420T
Overview
Overview
Usage
The XP is a mechanically linked fixed ratio system that
can mix and spray most two-component epoxy and urethane protective coatings. When using quick-setting
material (less than 10 minute pot life) a remote mix manifold must be used or materials must mix at the gun.
Quickset manifold 24M398 is recommended for
quick-setting material.
The two pumps are carbide seat severe duty positive
displacement pumps that displace fluid on both strokes.
The XP systems 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 Important Two-Component Material
Information, page 7, to determine the appropriate
location for your particular XP model.
Over Pressure Protection
Mechanically linked pumps can create excessive fluid
pressure if the full motor force is applied to only one
of the fluid pumps.
• Cart-Mounted Systems Only: Maximum air pres-
sure set point blow off valves are provided to limit
maximum fluid pressure. Do not remove these
valves.
• Color coded automatic over pressure relief
valves are used on cart-mounted systems to
dump excess fluid pressure back to the supply.
Never plug these return hoses. See Fluid Circu-
lation Manifold with Over Pressure Relief
Valves on page 38.
• When using an XP bare pump package to build a
system, use the over pressure relief valves referenced above.
• Never install individual shut off valves on the “A”
and “B” lines. On cart-mounted systems, common handles link the fluid control valves.
• On models other than 1:1 mix ratio, a rupture disc
is provided on the small side fluid pump (pumps
72cc and smaller) as a back-up to the over pressure relief valve. If the rupture disc ever opens,
do not operate the machine until the over pressure valve and the rupture disc have been
replaced.
• If changing pump lowers or motor on your system, use the correct over pressure relief valves
from the chart on page 39.
3A0420T 9
Initial System Setup
Initial System Setup
1. Check the shipment for accuracy. Ensure you have
received everything you ordered. See Component
Identification, page 14.
2. Check for loose fittings and fasteners.
3. Install optional solvent flush pump kit 262393, if
ordered. See manual 310863 for instructions.
4. Mount and connect optional heaters, if ordered. See
the heater adapter kit manual 406861 for instructions and the heater manual 309524.
5. Install desiccant kits if using polyurethane isocyanates in hoppers. See manual 406739 for instructions.
6. Install circulation and return tube kits if you are feeding material from drums or remote hoppers. See
manual 309852 if you are feeding urethane material.
7. Install hopper or hose heat circulation kit 24M224, if
ordered. See 313259 for instructions.
NOTE: Supply return lines must be used.
8. Connect the feed pumps, fluid strainers, and air
hoses as necessary. If your system does not use
hoppers, then see manual 312769.
9. Connect the air supply line. See Connect Air Sup-
ply, page 21.
10. Connect the fluid hose assembly, including the
static mixers, whip hose and gun. See Pressure
Relief Procedure, page 22.
11. Flush test oil from system as needed. See Empty
and Flush Entire System (new system or end of
job), page 29.
10 3A0420T
Models
The XP systems are approved for use in hazardous
locations only if the base model, all accessories, all
kits, and all wiring meet local, state, and national
codes.
Cart-Mounted Systems
Models
NOTE: All cart-mounted systems listed are Ex rated:
II 2 G
c IIA T2
See Accessories and Kits on page 55 for a list of all optional accessories.
NOTE: The “Standard” mix manifold selection means the mix manifold is mounted on the cart and comes with mix-
ers, 25 ft of 3/8 in. mix hose, and 10 ft of 1/4 in. whip hose. The “Quickset” mix manifold selection means the manifold
has dual flush valves, is mounted on a remote carriage, and comes with mixers and 10 ft of 1/4 in. whip hose. When
ordering the Quickset configuration, A and B hoses from the sprayer to the mix manifold must be ordered separately.
Volume
Typ
eModel
281000 --- --281101
281102 ✔
281105
281106 ✔
281201
281202 ✔
281205
281206 ✔
262804
281252 ✔
281255
281256 ✔
281301
281302 ✔
281305
XP35 with NXT 3400 Air Motor
281306 ✔
281401
281402 ✔
281405
281406 ✔
Pump
Package
281100 1.0:1 3500 (24, 241) 95 (0.65, 6.5) 38:1
281200 2.0:1
262803 2.5:1
281300 3.0:1
281400 4.0:1
Ratio
Mix
7 Gallon
Hoppers
Mix
Manifold Hose Gun
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
XTR5
XTR5
XTR5
XTR5
XTR5
Max Fluid
Working Pressure
psi (MPa, bar)
--- --- ---
3500 (24, 241) 85 (0.59, 5.9) 40:1
3500 (24, 241) 90 (0.62, 6.2) 34:1
3500 (24, 241) 100 (0.7, 7) 36:1
3500 (24, 241) 95 (0.65, 6.5) 38:1
Max Air
Pressure
psi (MPa, bar)
Pressure
Ratio
3A0420T 11
Models
Volume
Typ
e Model
282000 --- --282101
282102 ✔
282105
282106 ✔
282151
282152 ✔
282155
282156 ✔
282201
282202 ✔
282205
282206 ✔
282251
282252 ✔
282255
282256 ✔
282301
282302 ✔
282305
282306 ✔
282331
XP50 with 6500 Air Motor
282332 ✔
282401
282402 ✔
282405
282406 ✔
283101
283102 ✔
283201
283202 ✔
283301
283302 ✔
283401
283402 ✔
571000 --- --571101
571102 ✔
571151
571152 ✔
571201
571202 ✔
571251
571252 ✔
571301
571302 ✔
571401
XP70 with NXT 6500 Air Motor
571402 ✔
Pump
Package
282100 1.0:1 4500 (31, 310) 100 (0.7, 7) 45:1
282150 1.5:1
282200 2.0:1
282250 2.5:1
282300 3.0:1
282330 3.3:1
282400 4.0:1 4800 (33, 331) 100 (0.7, 7) 48:1
282100 1.0:1
282200 2.0:1 4800 (33, 331) 100 (0.7, 7) 48:1
282300 3.0:1 4500 (31, 310) 100 (0.7, 7) 45:1
282400 4.0:1 4800 (33, 331) 100 (0.7, 7) 48:1
571100 1.0:1 7250 (50, 500) 95 (0.65, 6.5) 76:1
571150 1.5:1 7250 (50, 500) 80 (0.5, 5.5) 91:1
571200 2.0:1 7250 (50, 500) 95 (0.65, 6.5) 76:1
571250 2.5:1 6500 (45, 448) 100 (0.7, 7) 65:1
571300 3.0:1 6800 (47, 469) 100 (0.7, 7) 68:1
571400 4.0:1 7250 (50, 500) 100 (0.7, 7) 73:1
Ratio
Mix
7 Gallon
Hoppers
Mix
Manifold Hose Gun
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
Quickset
Standard
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
10 ft
(3.0 m)
35 ft
(10.7 m)
XTR5
XTR5
XTR5
XTR5
XTR5
XTR5
FlexPlus
XTR7
Max Fluid
Working Pressure
psi (MPa, bar)
--- --- ---
5000 (34, 344) 90 (0.62, 6.2) 55:1
4500 (31, 310) 100 (0.7, 7) 48:1
5000 (34, 344) 95 (0.65, 6.5) 52:1
4500 (31, 310) 100 (0.7, 7) 45:1
5000 (34, 344) 90 (0.62, 6.2) 56:1
4500 (31, 310) 100 (0.7, 7) 45:1
--- --- ---
Max Air
Pressure
psi (MPa, bar)
Pressure
Ratio
12 3A0420T
Bare Proportioning Pump Packages
Models
Packages include motor, pump lowers, and all connection hardware.
Building systems with bare proportioning pump
packages:
• Over Pressure Protection must be used, see
page 9. See chart on page 39 to identify the over
pressure relief valves to use with your system.
• All components must meet or exceed maximum
working pressures.
Combined
Fluid
Output
cc/cycle
435 1.75:1 4.6 (17.4) 3150 (22, 217) 1800 (12, 124) Purple
435 1.75:1 4.6 (17.4) 3150 (22, 217) 1800 (12, 124) Purple
407 1.88:1 4.3 (16.3) 3400 (23, 234) 1800 (12, 124) Purple
388 1.97:1 4.1 (15.5) 3500 (24, 241) 1800 (12, 124) Purple
360 2.10:1 3.8 (14.4) 3800 (26, 262) 1800 (12, 124) Purple
Pressure
Ratio
Type
XP35 with
XP50 with
XP70 with
XP-h with
Volume
Pump
Package
281100 L090C0 L090C0 1.0:1 180 38:1 1.9 (7.2) 3500 (24, 241) 95 (0.65, 6.5)
281200 L115C0 L058C0 2.0:1 173 40:1 1.8 (6.8) 3500 (24, 241) 85 (0.59, 5.9)
262803 L14AC0 L058C0 2.5:1 202 34:1 2.1 (7.9 3500 (24, 241) 100 (0.7, 7)
281300 L14AC0 L048C0 3.0:1 192 36:1 2.0 (7.6) 3400 (23, 234) 95 (0.65, 6.5)
Air Motor
NXT 3400
281400 L14AC0 L036C0 4.0:1 180 38:1 1.9 (7.2) 3500 (24, 241) 90 (0.62, 6.2)
282100 L14AC0 L14AC0 1.0:1 288 45:1 3.1 (11.7) 4500 (31, 310) 100 (0.7, 7)
282150 L14AC0 L097C0 1.5:1 240 55:1 2.6 (9.8) 5000 (34, 345) 90 (0.62, 6.2)
282200 L18AC0 L090C0 2.0:1 270 48:1 2.9 (11.0) 4800 (33, 331) 100 (0.7, 7)
282250 L18AC0 L072C0 2.5:1 252 52:1 2.7 (10.2) 5000 (34, 345) 95 (0.65, 6.5)
282300 L22AC0 L072C0 3.0:1 288 45:1 3.1 (11.7) 4500 (31, 310) 100 (0.7, 7)
Air Motor
NXT 6500
282330 L18AC0 L054C0 3.3:1 234 56:1 2.5 (9.5) 5000 (34, 345) 95 (0.65, 6.5)
282400 L22AC0 L054C0 4.0:1 270 48:1 2.9 (11.0) 4800 (33, 331) 100 (0.7, 7)
571100 L090C0 L090C0 1.0:1 180 72:1 1.9 (7.2) 7250 (50, 500) 100 (0.7, 7)
571150 L085C0 L058C0 1.5:1 144 91:1 1.5 (5.6) 7250 (50, 500) 80 (0.55, 5.5)
571200 L115C0 L058C0 2.0:1 174 76:1 1.8 (6.8) 7250 (50, 500) 95 (0.65, 6.5)
571250 L14AC0 L058C0 2.5:1 203 65:1 2.1 (7.9) 6500 (45, 448) 100 (0.7, 7)
Air Motor
NXT 6500
571300 L14AC0 L048C0 3.0:1 193 68:1 2.0 (7.5) 6500 (45, 448) 100 (0.7, 7)
571400 L14AC0 L036C0 4.0:1 181 73:1 1.9 (7.2) 7250 (50, 500) 100 (0.7, 7)
284101 L22AC0 L22AC0
284102 L14AC0 L14AC0 293 2.63:1 3.1 (11.7) 4700 (32, 324) 1800 (12, 124) Gold
284103 L090C0 L090C0 180 4.21:1 1.9 (7.2) 7150 (49, 493) 1700 (12, 117) Silver
284201 L29AC0 L14AC0
284202 L18AC0 L090C0 274 2.81:1 2.9 (11.0) 5050 (35, 348) 1800 (12, 124) Gold
284203 L115C0 L058C0 170 4.39:1 1.8 (6.8) 7200 (50, 496) 1650 (11, 114) Silver
284251 L29AC0 L115C0
284252 L18AC0 L072C0 255 3.02:1 2.7 (10.2) 5000 (34, 345) 1650 (11, 114) Gold
284253 L14AC0 L058C0 199 3.77:1 2.1 (7.9) 6800 (47, 469) 1800 (12, 124) Silver
Viscount II
284301 L29AC0 L097C0
Hydraulic Motor
284302 L22AC0 L072C0 293 2.63:1 3.1 (11.7) 4700 (32, 324) 1800 (12, 124) Gold
284303 L14AC0 L048C0 189 3.95:1 2.0 (7.6) 7100 (49, 490) 1800 (12, 124) Silver
284401 L29AC0 L072C0
284402 L22AC0 L054C0 274 2.80:1 2.9 (11.0) 5000 (34, 345) 1800 (12, 124) Gold
284403 L14AC0 L036C0 180 4.21:1 1.9 (7.2) 7150 (49, 493) 1700 (12, 117) Silver
A Side
Pump
B Side
Pump
Mix
Ratio
1.0:1
2.0:1
2.5:1
3.0:1
4.0:1
NOTE: All pump packages are Ex rated except for the
XP-h pump packages (284xxx):
II 2 G
c IIA T2
Hydraulically powered pump packages (XP-h) are not
available as complete systems. Refer to manual 307158
for hydraulic application information.
Pump sizes are marked on the pump cylinder; sizes are
nominal. See technical data in manual 311762 for actual
displacement.
Over
Fluid Flow
at 40 cpm
gpm (lpm)
Maximum Fluid
Working
Pressure
psi (MPa, bar)
Maximum Air/
Hydraulic Oil
Working Pressure
psi (MPa, bar)
Ex
Rated
✔
Pressure
Relief
Valve To
Use
Purple
Gold
Silver
3A0420T 13
Component Identification
Component Identification
E
X
M
B
G
A
R
Mounting Components for
Pump Package
H
U
N
F
P
V
A
B
T
S
C
J
D
D
D
W
FIG. 1: XP70 system with optional accessories
Key:
A Air Supply Hose for Motor
B Main Air Controls; see page 15
C Air Inlet - 3/4 npsm(f)
D High Pressure Fluid Pump
EMotor
F Fluid Heater (optional)
G Solvent Flush Pump (optional); see page 16
H Solvent Flush Pump Air Controls; see page 16
J 7 Gallon Hoppers (optional)
KCart
L Brake
M Handle (lift to release)
Y
K
L
r_571101_3a0420a_1a-2
N Fluid Control Assembly; see page 15
P Tie Rods
R Motor Adapter Plate
S Adjustable Packing Nuts with Wet Cups
T Yoke With Rod Bearings
U Recirculation Lines
V Yoke Position Nut
W Static Mixer Tubes with Replacement Plastic Elements
X Motor Position Indicator Lines; see Motor Position on
page 20
Y Over Pressure Rupture Disc;
only 38cc, 48cc, 54cc, 58cc, and 72cc pumps
14 3A0420T
Fluid Control Assembly
Standard Mix Manifold shown
AA
AH
AF
AE
AJ
AB
AL
AC
AM
Component Identification
Key:
AA Fluid Manifold
AB Mix Manifold
AC Circulation Handle
AD Solvent Flush Valve
AE Dual Shutoff Handle
AF Fluid Pressure Gauges
AG Fluid Supply Inlet (Behind Fluid Manifold)
AH Fluid Circulation Fittings
AJ B Component Adjustable Fluid Restrictor; see
page 27
AK A and B Mix Manifold Check Valves
AL Solvent Inlet Check Valve
AM Automatic, Spring Loaded, Color-Coded Over
Pressure Relief Valves; with grease fittings; see
page 39
AN A and B Combined Outlet; 3/8 npt(m)
AN
FIG. 2
Main Air Controls
CE
CC
ti19167a
CB
CD
AK
AD
CA
Key:
CA Main Motor Shutoff Valve (Relieving)
CB Main Motor Air Pressure Regulator
CC Air Filter with Auto Drain
CD Main Motor Air Pressure Gauge
CE Filtered Air Distribution Manifold
FIG. 3
3A0420T 15
Component Identification
45:1 Solvent Flush Pump Kit 262393 (optional)
Pump
Key:
BA Solvent flush pump (Merkur Pump)
BA
BD
BF
BE
BB Fluid Inlet
BD Muffler
BE Prime/Flush/Sample valve
BF Fluid Outlet Hose
BG Circulation hose
FIG. 4
Air Controls
DC
DE
DB
BG
BB (suction hose not shown)
r_571100_3a0420a_4a-2
Key:
DA Solvent Pump Air Shutoff Valve (Relieving)
DB Solvent Pump Air Pressure Regulator
DC Solvent Pump Air Pressure Gauge
DD Air Outlet
DE Air Inlet
DA
DD
r_571101_3a0420a_5a-2
FIG. 5
16 3A0420T
Component Identification
Air Line
• Bleed-type master air valve (CA): Required in
your system to relieve air trapped between it and
the air motor when the valve is closed. Be sure the
valve is easily accessible from the pump and
located downstream from the air regulator.
Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.
• Pump air regulator (CB): Controls pump speed
and outlet pressure.
• Air line filter (C): 40 micron filter removes harmful
dirt and moisture from compressed air supply. Accumulated water is automatically drained from the filter.
Fluid Line Accessories
Optional Accessories
• Optional Fluid Heaters (N): Heats the resin and
hardener before mixing. Improves the chemical
reaction and lowers viscosity to improve the spray
pattern.
• Optional Solvent Flush Kit (G): Flushes the mix
manifold. Includes a solvent pump, mounting hardware, and solvent supply hose.
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 using the equipment. See
Empty and Flush Entire System (new system or end
of job), page 29.
• Fluid Manifold (AA): Controls circulation and pump
priming.
• Mix Manifold (AB): Combines A and B fluid into
one fluid line.
• Circulation Handle (AC): Directs fluid flow for cir-
culation or mixing. Move to open position to relieve
fluid pressure, prime pumps, and circulate material
in hoppers. Move to closed position to spray mixed
material.
• Dual Shutoff Handle (AE): Controls A and B fluid
flow for mixing and dispensing. Close before flushing.
• Solvent Flush Valve (AD): Controls solvent flow to
the mix manifold, hose, and spray gun.
• Static mixer/gun hose kit: Thoroughly mixes the
two fluids and delivers the mixed fluid to the spray
gun. Includes static mixer and hoses to the spray
gun.
3A0420T 17
Setup
Setup
Location
The XP35, XP50, and XP70 systems are approved
for use in hazardous locations only if the base model,
all accessories, all kits, and all wiring meet local,
state, and national codes.
1. Locate the proportioner on a level surface.
2. Position the proportioner for convenient operator
access and maintenance, safe routing of air and
fluid lines, and easy connection of components and
accessories.
3. For permanent mounting, remove wheels and
mount the frame to the floor. See Dimensions,
page 58.
4. Ensure that the cart brake (L) is in the locked position.
Grounding
Pump: use ground wire and clamp (supplied). Loosen
grounding lug locknut (W) and washer (X). Insert ground
wire end (Y) into lug (Z) slot and tighten locknut
securely. Connect ground clamp to a true earth ground.
Y
W, X, Z
Solvent Pump: use ground wire and clamp (supplied
with solvent pump). Follow instructions in pump manual.
Air and fluid hoses: use only static dissipation type
hoses with a maximum of 500 ft (150 m) combined hose
length to ensure grounding continuity. Check electrical
resistance of hoses regularly. If total resistance to
ground exceeds 29 megohms, replace hose immediately.
Air compressor: follow manufacturer’s recommendations.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container: follow local code.
The equipment must be grounded. Grounding
reduces the risk of static and electric shock by providing an escape wire for the electrical current due to
static build up.
18 3A0420T
Object being sprayed: follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray gun
firmly to the side of a grounded metal pail, then trigger
the gun.
Wire Systems with Explosion-Proof Heaters
(Hazardous location systems only)
If your system is rated for hazardous areas, and you
have explosion-proof heaters, you must have a qualified electrician connect heater wiring. Ensure wiring
and installation comply with local electrical codes for
hazardous areas.
Improperly installed or connected equipment will create
a hazardous condition and cause fire, explosion, or
electric shock. Follow local regulations.
When explosion-proof heaters are used, ensure the wiring, wiring connections, switches, and electrical distribution panel all meet flame-proof (explosion-proof)
requirements.
Setup
Refer to the Viscon HP heater manual for electrical connection instructions and guidelines in hazardous locations.
3A0420T 19
Setup
Motor Position
The motor position must be set for the volume mix ratio
of the system.
NOTE: Changing the motor position does not change
the mix ratio.
Check Motor Position
1. Verify that the correct pumps are mounted for your
mix ratio by volume. See chart in Bare Proportion-
ing Pump Packages on page 13.
indicator line
indicator line
Air Motor shown
FIG. 6: Ratio indicators
r_258914_3a0420a_10b
3. Place wrench on adapter rod (104) then use supplied tool to loosen the serrated yoke nut (V) above
the yoke (T).
104
Air Motor shown
V
T
r_571101_3a0420a_2a-2
4. Loosen the three nuts (P2) below the motor tie rods.
E
piston rod
V
P2
T
2. Verify that the motor position is adjusted correctly
for that mix ratio. See F
IG
. 6. If not, perform the fol-
lowing Change Motor Position procedure.
Change Motor Position
There are specific motor positions for each mix ratio setting. To adjust the position of the air motor:
1. Perform Check Motor Position procedure. If position is incorrect, continue to next step.
2. Loosen the eight fasteners and remove the two
pump guards.
Air Motor shown
fastener
pump guard
fastener
r_258914_3a0420a_5a
Air Motor shown
FIG. 7
5. Grab the piston rod and slide the position of the
motor (E) until the indicator lines are aligned with
your ratio. See F
IG
. 6 and FIG. 7.
NOTICE
Do not hit tie rods (P) with a steel hammer. Damage
to the air motor base may result.
6. Tighten the three nuts (P2) and yoke nut (V).
7. Use supplied tool to tighten the yoke nut.
8. Install the pump guards.
pump guard
r_258914_3a0420a_4a-1
20 3A0420T
Setup
Connect Air Supply
1. Connect the air supply hose to the 3/4 npt(f) air filter
inlet (C).
NOTE: Use a 3/4 in. (19.1 mm) ID minimum air hose.
Air consumption is 75 cfm per gallon per minute
spraying. Do not use pin fitting type quick disconnects.
C plug
r_571100_3a0420a_10a-1
FIG. 8
2. Remove plugs as necessary for solvent pump and
feed supply pump air hoses. See pump manuals for
setup instructions. See F
IG
. 8.
Connect Fluid Hose Bundles (Remote Mix Manifold Only)
Connect additional fluid hoses to the fluid manifold (AA)
when the mix manifold (AB) is remote. Hoses must be
properly sized and balanced for your mix ratio. See mix
manifold manual for details.
1. Connect the resin and hardener hoses to the resin
and hardener outlets on the proportioner fluid manifold and resin and hardener inlets on the mix manifold.
AB
AN
W
Connect Static Mixers, Gun, and Hoses
NOTICE
To prevent creating a flare on the mixer tube, do not
use a union swivel end on the mix tube inlet.
1. Connect the outlet of the two primary static mixer
tubes with mixer elements (W) to the fluid mix
hose (25), cleanup mixer (27, 28), whip hose (30),
and spray gun (31). See F
2. Add mixed material hose as necessary between the
mix hose (25) and cleanup mixer (27, 28).
IG
. 9.
25
Standard Mix Manifold shown
FIG. 9
27, 28
30
31
r_571100_3a0420a_43a
3A0420T 21
Pressure Relief Procedure
Pressure Relief Procedure
Follow Flush Mixed Material, page 28 when you
stop spraying or dispensing; and before cleaning,
checking, servicing, or transporting equipment.
8. Engage the trigger lock.
9. Close the dual shutoff handle (AE) and open the circulation handle (AC).
AC
Relieve A and B Fluid Pressure
1. Engage the trigger lock.
TI1949a
2. Close the main air shutoff valve (CA).
CA
r_571100_3A0420A_11a-1
3. Shut off heaters, if used.
4. Shut off feed pumps, if used.
5. Remove the spray tip and clean.
6. Disengage the trigger lock.
AE
r_571101_3A0420A_9a-2
10. Always flush the mix hose after relieving A and B
fluid pressure through the mix manifold. See Flush
Mixed Material, page 28.
11. Shutoff the solvent supply pump and repeat steps
6-8 to relieve solvent pressure.
If the mixed material has already been flushed, but
pressure remains on the A and B pumps, pressure
can be relieved back to the hoppers (J).
a. Close the main air shutoff valve (CA).
b. Open the circulation handle (AC).
NOTE: For longer valve life in abrasive fluids, it is
advisable to relieve high pressure out through the
gun when possible.
12. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved after following the steps above, very slowly loosen tip guard
retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Clear hose
or tip obstruction.
13. If static mixer, whip hose, and gun cannot be
flushed because of mixed and cured material, very
slowly loosen static mixer tube from mix manifold
TI1950a
TI1953a
outlet to relieve pressure gradually, then loosen
completely. Replace or clean clogged components.
7. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
22 3A0420T
Prime Empty System
Prime Empty System
Prime A and B Fluids
Wear gloves when using flush solvents and/or if the
fluid temperature exceeds 110°F (43°C).
NOTE: The equipment is tested with mineral oil at
the factory. If necessary, flush out the oil with a
compatible solvent before spraying. See Empty and
Flush Entire System (new system or end of job),
page 29.
Do not install the gun spray tip yet. To avoid splashing, use the lowest pressure possible to prime.
1. Condition the materials prior to adding to the hoppers (J). Ensure that the resin materials are thoroughly mixed, homogenous, and pourable prior to
adding to the hopper. Stir the hardeners back into
suspension prior to adding material to hopper.
2. Fill the A and B reservoirs with proper materials. Fill
the A side (blue) with major volume of material; fill
the B side (green) with minor volume of material
(unless 1:1 mix ratio).
3. Move the recirculation lines (U) to empty containers.
U
4. Close the dual shutoff handle (AE) and open the circulation handle (AC).
AC
AE
r_571101_3A0420A_9a-2
5. Open the main air shutoff valve (CA).
J
CA
6. Slowly open the air regulator (CB).
7. Dispense fluid into the containers until clean fluid
comes out of the A and B recirculation lines.
8. Decrease air pressure. Close the main air shutoff
valve (CA).
9. Move the recirculation lines (U) back to the correct
hopper (J).
10. If using heaters, heat fluid throughout system before
spraying. See Recirculate Prior to Spraying or
Re-Prime After a Pump Runs Dry, page 25.
3A0420T 23
Prime Empty System
Prime Solvent Flush Pump
Follow instructions if the optional solvent flush pump kit
is used.
1. Connect the flush pail ground wire to a metal pail of
solvent.
2. Place the siphon tube and the solvent circulation
hose (BG) in the pail of solvent.
BG
BE
r_571101_3A0420A_5b-2
3. Open the solvent prime valve (BE) on the solvent
pump (BA) outlet.
4. Open the solvent pump air valve (DA). Slowly turn
the solvent pump air regulator (DB) clockwise to
prime the solvent pump and route solvent back to
the pail. Close the solvent pump fluid valve (BE) and
air valve (DA).
6. Ensure the trigger lock is engaged. Remove the
spray tip.
TI1949a
4)!
TI1948a
7. Disengage the trigger lock and trigger the gun into a
grounded pail. Use a pail lid with a hole to dispense
through. Seal around the hole and gun with a rag to
prevent splash back. Be careful to keep fingers
away from the front of the gun.
TI1950a
TI1953a
8. Open the solvent pump air valve (DA). Slowly turn
the solvent pump air regulator (DB) clockwise to
prime the solvent pump and push air out of the mix
hose and gun. Trigger the gun until all air is purged.
9. Close the solvent pump air valve (DA) and trigger
the gun to relieve pressure. Engage the trigger lock.
DB
DA
TI1949a
DA
r_571101_3A0420A_5a-2
5. Open the solvent flush valve (AD) on the mix manifold.
10. Close the solvent flush valve (AD).
NOTE: Solvent pump air and pressure may be left
r_571101_3A0420A_12a-2
on while spraying. Never spray mixed material without the solvent pump and hose primed with solvent.
AE
(closed)
AB
AD
24 3A0420T
Prime Empty System
Recirculate Prior to Spraying or Re-Prime After a Pump Runs Dry
NOTE: Agitate, recirculate, and heat the material
only as necessary to avoid mixing air into the fluid.
Use the recirculation mode when heating the material is
required. Note the temperature at the top of the heater
(outgoing or back to the hopper). When the thermometer reaches operating temperature, the material is ready
to spray.
If using a system that does not require heat, recirculation is still required prior to spraying. Recirculation
ensures that any settled fillers are mixed in, the pump
lines are fully primed, and the pump check valves are
operating smoothly.
Recirculation also allows you to re-prime one side that
has run dry.
1. Follow Prime Empty System, page 23.
2. Close the dual shutoff handle (AE).
AC
5. Turn down the air pressure regulator (CB) and then
open the main air shutoff valve (CA). Use the air
pressure regulator to slowly increase the air pressure to the pumps until they start running slowly.
CB
CA
6. Run the pumps for a few minutes or until the material has reached the desired temperature. See Heat
Fluid.
7. Close the main air shutoff valve (CA).
CA
AE
r_571101_3A0420A_9a-2
3. Ensure the recirculation hoses (U) are in the correct
hoppers (J).
U
J
4. Open the circulation valve handle (AC).
r_571100_3A0420A_11a-1
8. See Spray, page 26.
Heat Fluid
To heat fluid evenly throughout the system:
1. Circulate the fluid at approximately 1/2 gpm
(10-20 cycles/min.) to raise the temperature of the
hoppers to 80-90° F (27-32° C).
2. Decrease the circulation rate to approximately
0.25 gpm (5 cycles/min.) to increase the heater outlet temperature to match the spray temperature.
NOTE: Circulating the fluid too quickly without
decreasing the circulation rate will increase only the
hopper temperature. Similarly, circulating fluid too
slowly will increase only the heater outlet temperature.
3A0420T 25
Spray
Spray
Wear gloves when using flush solvents and/or if fluid
temperature exceeds 110°F (43°C).
5. Engage the trigger lock. Install the tip on the gun.
NOTE: After the first day of spraying follow Pressure Relief Procedure, page 22, and tighten the
throat packing nuts on both pumps.
1. If heaters are used, turn them on. To adjust the
heater temperature, refer to the Viscon HP manual
for instructions, and the Heat Fluid section, page
25. Circulate as necessary.
2. Close the circulation handle (AC) and the solvent
flush valve (AD). Open the dual shutoff handle (AE).
AC
AE
AD
3. Adjust the main air regulator (CB) to 30 psi
(0.21 MPa, 2.1 bar).
4. Remove tip. Disengage the trigger lock and trigger
the gun into a grounded metal pail. Use a metal pail
lid with a hole to dispense through to avoid splashing. Dispense out of the mix hose until a well mixed
coating flows from the gun.
TI1949a
6. Adjust the main pump air regulator (CB) to the necessary spraying pressure and apply a coating to a
test panel.
NOTE: Run system verification tests everyday. See
page 31.
7. Excess pressure increases overspray and pump
wear.
8. Check and record gauge readings frequently during
operation. A change in gauge readings indicates a
change in system performance.
NOTE:
• A pressure drop occurs during pump stroke
changeover. It should be quick and synchronous.
• Flush the mix manifold as necessary during the
day’s operation.
9. Follow Flush Mixed Material, page 28 when you
are finished spraying or before potlife expires.
NOTE: Mixed material potlife or working time
decreases with increased temperature. Pot life in
the hose is much shorter than the dry time of the
coating.
TI1950a
26 3A0420T
TI1953a
B Side Mix Manifold Restriction
The B side restrictor (AJ) controls “lead/lag” ratio errors
of the A and B flow into the static mixer tubes. These
errors occur momentarily when the gun opens. The
error is caused by differences in viscosity, volume, and
hose expansion.
The restrictor is used primarily when the mix manifold is
positioned remote from the machine with a short mix
hose to the spray gun. It can also be used in the ratio
check procedure.
B Side Mix Manifold Restriction
AJ
AB
If the mix manifold (AB) is mounted on the machine, you
do not need to adjust the restrictor. Leave open two
turns minimum.
To Adjust the Restrictor:
Adjust the restrictor stem clockwise while spraying until
you see a slight rise in the B side pressure gauge. The
point where the pressure starts to rise is a good adjustment setting.
NOTE: Unless you are dispensing directly out of the
mix manifold and mixer, this is an approximate
adjustment.
See the mix manifold manual for more information.
3A0420T 27
Flush Mixed Material
Flush Mixed Material
Flush the mix manifold when any of the following situations occur.
• breaks in spraying
• overnight shutdown
• mixed material in system approaching end of potlife
To flush the entire system, see Empty and Flush
Entire System (new system or end of job), page 29.
Flush Mix Manifold, Hose, and
4. Open the solvent flush valve (AD).
AB
AD
5. Disengage the trigger lock and trigger gun into a
grounded pail. Use a pail lid with a hole to dispense
through. Seal around the hole and gun with a rag to
prevent splash back. Be careful to keep fingers
away from the front of the gun. Continue flushing
until clean solvent dispenses.
Spray Gun
If your system doesn’t include a solvent flush pump, see
step 2 of Empty and Flush Entire System (new sys-
tem or end of job), page 29.
Turn off heaters. Allow heater and heated hoses to cool.
Use Optional Solvent Pump
1. Close the main air shutoff valve (CA) to turn off the
system. Engage trigger lock. Remove the spray tip
and soak in solvent.
CA
TI1949a
r_571100_3A0420A_11a-1
2. Close the dual shutoff handle (AE).
3. Open the solvent pump air valve (DA). Slowly turn
the solvent pump air regulator (DB) clockwise to
increase air pressure.
TI1950a
TI1953a
6. Close the solvent pump air valve (DA). Trigger the
gun to relieve pressure. Close the solvent flush
valve (AD) after relieving the pressure.
DA
AD
r_571101_3A0420A_12a-2
r_571101_3A0420A_12a
7. Follow Pressure Relief Procedure, page 22.
8. Engage the trigger lock. Disassemble and clean the
spray tip with solvent by hand. Reinstall on the gun.
DB
DA
r_571101_3A0420A_5a-2
28 3A0420T
TI1949a
4)!
TI1948a
Empty and Flush Entire System (new system or end of job)
Empty and Flush Entire System
(new system or end of job)
2. Engage the trigger lock. Turn the main pump air
regulator (CB) fully counter-clockwise to shut off.
NOTE:
• If the system includes heaters and heated hose,
turn them off and allow to cool before flushing.
Do not turn on the heaters until the fluid lines
are clear of solvent.
• Cover fluid containers and use the lowest possible pressure when flushing to avoid splashing.
• Before color change or shutdown for storage,
circulate the solvent at a higher flow rate and for
a longer time. Change the solvent when it gets
dirty.
• To only flush the fluid manifold, see Flush Mix
Manifold, Hose, and Spray Gun, page 28.
• If the machine is inoperable, use drain plugs on
the pump inlet fittings.
Guidelines
Flush new systems if the coating materials will be contaminated by mineral oil.
Flushing will help prevent materials from settling or gelling in the pumps, lines, and valves. Flush the system
when any of the following situations occur.
• anytime the system will not be used for more
than one week (depending on materials used)
• if the materials used have fillers that will settle
• if using materials that are moisture sensitive
• before servicing
• if the machine is going into storage, replace the
flush solvent with light oil. Never leave the
equipment empty of any fluid.
CB
TI1949a
r_571100_3A0420A_11a-1
3. Move the recirculation lines (U) to separate fluid
containers to pump remaining fluid out of the system.
U
4. Open the circulation handle (AC). See F
page 15.
5. Increase the main pump air regulator (CB) pressure
to 20 psi (138 kPa, 1.38 bar).
6. Open the main air shutoff valve (CA).
CB
IG
. 2 on
Procedure
1. Follow Prime Empty System, page 23 and Flush
Mix Manifold, Hose, and Spray Gun, page 28, as
required.
3A0420T 29
NOTE: If the system does not start with static pressure, increase the air pressure by 5 psi (35 kPa,
0.35 bar) increments. To avoid splashing, do not
exceed 35 psi (241 kPa, 2.4 bar).
CA
Shutdown
7. Run the pumps until the A and B hoppers (J) are
empty. Salvage the material in separate, clean containers.
8. Close the main air shutoff valve (CA).
CA
r_571100_3A0420A_11a-1
9. Wipe the hoppers (J) clean, then add solvent to
each. Move the circulation lines (U) to waste containers and push out the dirty fluids.
10. Move the recirculation lines (U) back to the hoppers.
Continue recirculating until the system is thoroughly
flushed.
U
14. Close the dual shutoff handle (AE).
15. Remove pump fluid filters, if installed, and soak in
solvent. Clean and replace the filter cap. Always
replace the filter o-rings.
NOTE:
• Fill the A and B pump packing nuts with TSL.
Also, 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.
• If machine is set up with a remote mix manifold,
the A and B hose can be disconnected from the
mix manifold, and secured in back of each hopper for circulation of flush solvent.
• Change the flush solvent at least once until it
circulates clean.
• Always keep the A side and B side flush solvent
separate.
J
11. Close the circulation handle (AC) and open the dual
shutoff handle (AE).
12. Dispense fresh solvent through the mix manifold
valves and out the gun.
13. Turn off the air motors and follow Pressure Relief
Procedure, page 22.
AC
AE
Shutdown
1. Follow Pressure Relief Procedure, page 22.
2. Flush mix manifold, hoses, and gun. See Flush Mix
Manifold, Hose, and Spray Gun, page 28.
3. Close the main air shutoff valve (CA).
Park
1. Open the circulation handle (AC) and adjust the air
regulator (CB) so that the pump runs slowly.
2. Close the circulation handle (AC) when the pump is
at the bottom of the stroke.
3. Close the air regulator (CB) and open the circulation
handle (AC).
AD
30 3A0420T
System Verification
System Verification
Graco recommends running the following tests daily.
Check for Normal Operation
Every time you start spraying:
• Watch the fluid gauges (AF). A pressure drop
occurs during pump stroke changeover. It should be
quick and synchronous.
• Stop the pumps on the upstroke. Check that both
gauges hold pressure for at least 20 seconds. See
Pump Troubleshooting on page 34.
NOTE: If one gauge drops, the others will rise.
• Stop the pumps on the downstroke. Check that all
gauges hold pressure.
• If using feed pumps, check that both feed pumps
run during the proportioner upstroke.
Mix and Integration Tests
Use the following tests to check for proper mix and integration.
NOTE: Spots that take longer to cure indicate insufficient pump loading, leakage, or lead/lag errors at a
remote mix manifold.
Appearance Test
Spray material onto foil. Look for variations in color,
gloss, or texture that may indicate improperly catalyzed
material.
Monitor Fluid Supply
NOTICE
To prevent pumping air into the system, which causes
incorrect proportioning, never allow the feed pump or
solvent pump containers to run dry.
An empty pump will quickly accelerate to a high speed,
and may damage itself and the other displacement
pump because it causes a pressure rise in the other
pump. If a supply container runs dry, stop the pump
immediately, refill the container, and prime the system.
Be sure to eliminate all air from the system.
Check Pot Life
Butterfly Test
At low pressure, and with the spray tip reversed, dispense a 1/2 in. (12.7 mm) bead of material onto foil until
multiple changeovers of each pump have occurred. Fold
the sheet of foil over the fluid then peel it back and look
for unmixed material (appears marble-like), or color
changes.
Curing Test
Spray a single continuous pattern on foil at typical pressure setting, flow rate, and tip size until multiple changeovers of each pump have occurred. Trigger and
de-trigger at typical intervals for the application. Do not
overlap or cross over your spray pattern.
Check curing at various time intervals, listed on the
material data sheet. For example, check for dry to touch
by running your finger along the test pattern’s entire
length at the time listed on the data sheet.
Check the fluid manufacturer's instructions for fluid pot
life at your fluid temperature. Flush mixed fluid out of the
mix manifold, hose, and gun before pot life time expires,
or before a rise in viscosity affects the spray pattern.
Ratio Check
Check the ratio at the mix manifold after any changes to
the proportioning system. Use Ratio Check Kit 24F375
to check the ratio at the mix manifold. See manual ratio
check kit manual for instructions and parts.
NOTE: To prevent an inaccurate ratio check when
feed pumps are used in your system, the feed pressure cannot be more than a maximum of 25% of the
proportioner outlet pressure. High feed pressure
can float the proportioner pump check balls, resulting in an inaccurate ratio check. There must be back
pressure on both sides of the mix manifold when
checking the ratio.
3A0420T 31
Maintenance
Maintenance
Hose Electrical Resistance
Check electrical resistance of hoses regularly. If total
resistance to ground exceeds 29 megohms, replace
hose immediately.
Filters
Once a week check, clean, and replace (if needed) the
following filters.
• Both pump filters; see lower manual for instructions.
• Main air inlet manifold filter; see Replace Air Filter
Element, page 36.
• Spray gun handle filter; see spray gun manual.
Seals
Once a week, check and tighten throat seals on both
pumps. See table for torque specifications. Be sure to
follow the Pressure Relief Procedure, page 22, prior to
tightening seals. There must be zero pressure on the
pumps when adjusting.
Pump Size Torque Specification
All 25-30 ft-lb (34-41 N•m)
6. Shutdown the sprayer and turn off all power. See
Shutdown, page 30.
7. Clean the external surfaces only using a rag soaked
in solvent that is compatible with the spray material
and surfaces being cleaned.
8. Allow enough time for the solvent to dry before
using the system.
Recommended Spare Parts
Keep these spare parts on hand to reduce downtime.
See Recommended Spare Parts, page 54.
Change the Mix Ratio
In order to change the mix ratio, one or both pumps
need to be replaced, the air motor needs to be re-positioned, and the over pressure relief valves may need to
be installed.
NOTE: Only Xtreme XP lower pumps come with a
rod coupling.
1. Check the Varying Parts table on page 51 for the
correct pump sizes.
2. Remove and replace pump. See page 35.
3. Adjust the position of the air motor. See page 20.
Cleaning Procedure
1. Ensure all equipment is grounded. See Grounding,
page 18.
2. Ensure the area where the system will be cleaned is
well ventilated and remove all ignition sources.
3. Turn off all heaters and allow equipment to cool.
4. Flush mixed material. See Flush Mixed Material,
page 28.
5. Relieve pressure. See Pressure Relief Procedure,
page 22.
32 3A0420T
4. If changing from one type of XP system to
another (for example - changing from XP35 to
XP70 or from XP70 to XP35): remove the existing
over pressure relief valves (302) and install the correct valves for the new system type. See Replace
Over Pressure Relief Valves on page 38.
5. Change air pressure relief valve as required,
depending on ratio. See air relief valve (64) in tables
starting on page 46.
Troubleshooting
Troubleshooting
✖ Fluid ratio will be wrong.
◆ Purge all air from system before proportioning
fluids.
Problem Cause Solution
System stops or will not start. Air pressure or volume too low. Increase; check air compressor.
Closed or restricted air line or air
valve.
Fluid valves closed. Open.
Clogged fluid hose. Replace.
Air motor worn or damaged. Repair air motor; see 311238.
Displacement pump stuck. Repair pump; see 311762.
System speeds up or runs erratically. Fluid containers are empty.◆ Check often; keep filled.
Air in fluid lines.◆ Purge; check connections.
Displacement pump parts worn or
damaged.
Pump operates, but resin output
pressure drops on upstroke.✖
Pump operates, but resin output
pressure drops on downstroke.
Pump operates, but resin output
pressure drops on both strokes.✖
Pump operates, but hardener output
pressure drops on upstroke.✖
Pump operates, but hardener output
pressure drops on downstroke.✖
Pump operates, but hardener output
pressure drops on both strokes.
Fluid leak in packing nut. Loose packing nut or worn throat
Fluid leak under packing nut Packing cartridge o-ring. Replace o-ring; see 311762
Relief valve (AM) leaks back to supply, opens too soon, or will not close.
No pressure on hardener side; fluid
leaking from hardener pump outlet
rupture disc fitting.
Pressure and flow surges on
upstroke.
Dirty, worn, or damaged resin pump
piston valve or piston packings.
Dirty, worn, or damaged resin pump
intake valve.
Hardener output restriction. Clean, unplug hardener side. Open
Fluid supply low.◆ Refill or change container.
Dirty, worn, or damaged hardener
pump piston valve or piston packings.
Dirty, worn, or damaged hardener
pump intake valve.
Resin output restriction. Clean, unplug resin side.
Fluid supply low.◆ Refill or change container.
packings.
Relief valve is dirty or damaged. Replace over pressure relief
Overpressure rupture disk blown. Determine cause of overpressuriza-
Feed pressure too high. Every 1 psi
of feed pressure adds 2 psi during
upstroke.
Open or clean.
Repair pump; see 311762.
Clean, repair pump; see 311762.
Clean, repair pump; see 311762.
manifold restrictor.
Clean, repair pump; see 311762.
Clean, repair pump; see 311762.
Tighten; replace; see 311762.
valve (302)
tion and correct. Replace rupture disk
assembly 258962 (see page 51) and
over pressure relief valve (302).
Reduce feed pressure. See Techni-
cal Data, page 57.
3A0420T 33
Troubleshooting
Problem Cause Solution
Fluid outlet pressure gauges split
only at the top changeover (if one
Not fully loading one side on
upstroke.
Increase feed pressure on side that
dropped.
gauge drops the other will rise).
Increase feed hose size.
Clean inlet strainer or hopper screen.
Air mixed in fluid from excessive agi-
Flush and add new fluid.
tation or circulation.
Pump Troubleshooting
This chart uses proportioning fluid gauges to determine pump malfunctions. Observe the gauge readings during the
stroke direction indicated by the bold arrow, and immediately after closing the gun or mix manifold. Refer to other
manuals to troubleshoot individual components.
TROUBLE AREA:
Resin Pump Leakage
1. Throat packing
2. Piston packing
3. Piston ball check
Resin
Pump
Hardener
Pump
TROUBLE AREA:
Hardener Pump Leakage
1. Throat packing
2. Piston packing
3. Piston ball check
Resin
Pump
Hardener
Pump
TROUBLE AREA:
Resin Pump Leakage
1. Throat packing
2. Intake ball check
Resin
Pump
Falling Rising
r_258914_3a0420a_11a r_258914_3a0420a_11a
Hardener
Pump
TROUBLE AREA:
Hardener Pump Leakage
1. Throat packing
2. Intake ball check
Resin
Pump
FallingRising
Hardener
Pump
FallingFalling Rising Rising
r_258914_3a0420a_10ar_258914_3a0420a_10a
34 3A0420T
Repair
To avoid serious injury due to the pump assembly
falling, secure a hoist to the lift ring.
Follow Shutdown procedure on page 30, which
includes flushing, if service time may exceed pot life
time, before servicing fluid components, and before
transporting system to a service area.
Repair
4. Remove the spring clamp (130) and coupling (119
or 120).
106
135
105
Pump Assembly
The displacement pumps and air motor may be
removed and serviced separately or the entire pump
and motor assembly can be removed with a hoist.
Remove Pump Assembly
1. Stop the pumps near the bottom of their stroke. Fol-
low Shutdown, page 30.
2. Disconnect all hoses from the pump assembly.
3. If hoppers are installed, disconnect the hopper fluid
lines from the pump fluid inlet. See Hoppers, page
40.
NOTE: The hopper and hopper bracket do not need
to be removed from the cart.
4. Remove screws (6) and washers (5) under the tie
plate (101).
5. Use hoist to remove the pump assembly by the lift
ring and carefully lift out of cart (1).
130
119
117
118
108
r_258914_3a0420a_5a
5. Use a wrench to hold the tie rod (105, 106) flats to
keep the rods from turning. Unscrew the nuts (108)
from the tie rods and carefully remove the displacement pump (117 or 118) and lower straps (135).
6. Refer to the Xtreme Displacement Pump manual to
service or repair the displacement pump.
Remove Displacement Pump
1. Follow Shutdown, page 30.
2. If hoppers are installed, remove the hopper and
hopper bracket from the cart. See Hoppers, page
40.
3. If feed pumps are installed, close the inlet ball valve.
Remove inlet union (61).
3A0420T 35
7. Follow the steps in reverse order to reinstall the displacement pump.
NOTE: Torque nuts (108) to 50-60 ft-lb (68-81 N•m).
Repair
Remove Motor
1. Stop the pumps near the bottom of their stroke. Fol-
low Shutdown, page 30.
2. Disconnect the air line from the air motor (103).
3. Remove the air motor rod cover (121) and pump
guards (122).
Air Motor shown
122
r_258914_3a0420a_7a
4. Use a wrench to hold the tie rod (102) flats to keep
the rods from turning. Unscrew the nuts (108) and
washers (107) from the tie rods.
Air Motor shown
103
121
lift ring
8. Refer to the air motor manual to service or repair the
air motor.
9. Follow the steps in reverse order to reinstall the air
motor.
NOTE: Position air motor for correct mix ratio. See
Motor Position on page 20 for instructions. Torque
nuts (108) to 50-60 ft-lb (68-81 N•m).
Air Controls
See FIG. 10 on page 37.
Replace Air Control Assembly
1. Close the main air shutoff valve on the air supply
line and on the system. Depressurize the air line.
2. Disconnect the air motor air lines and system air
line.
3. Remove the nut (8) and washer (5). Remove the
bottom air control manifold assembly from the cart.
4. Loosen the upper air control assembly from the air
motor.
102
104
111
107
108
109
5. Place a wrench on adapter rod (104). Use tool (70)
to loosen the serrated yoke nut (109) that holds the
air motor (103) above the yoke (111).
6. Face the front of the machine and slide the air motor
(103) to the opening in the yoke (111).
r_258914_3a0420a_8a
5. Follow the steps in reverse order to reinstall the new
air control assembly.
Replace Air Filter Element
1. Close the main air shutoff valve on the air supply
line and on the system. Depressurize the air line.
2. Unscrew the serrated ring on filter bowl (210).
3. Remove and replace the filter element (210a). See
Air Controls, 258983, page 52.
Replace System Air Regulator
1. Close the main air shutoff valve on the air supply
line and on the system.
2. Disconnect air motor air lines and system air line.
3. Remove the regulator assembly (201) and replace
with new regulator. See Air Controls, 258983,
page 52.
4. Follow the steps in reverse order to reassemble.
7. Use a hoist to remove the air motor by the lift ring.
36 3A0420T
201
Repair
211
206
214
207
Air Flow
216
215
208
213
204
203
209
206
Air Flow
214
202
205
209
210
5, 8
r_571101_3A0420A_1a-2
FIG. 10: Air Control Assembly 258983
3A0420T 37
Repair
Mix Manifold Assembly
1. Follow Pressure Relief Procedure, page 22.
2. Disconnect the fluid hose (25) and the flush hose
from the mix manifold (36).
3. Loosen the union fittings (306) that connect to the
mix manifold adapter fittings.
4. Remove the mix manifold assembly (36).
5. See mix manifold manual for service and repair
instructions.
306
36
r_571101_3a0420a_38a
1
35
37
r_571101_3a0420a_39a
FIG. 11: Fluid Circulation Manifold
Replace Over Pressure Relief Valves
1. Flush before repairing equipment, if possible. See
Empty and Flush Entire System (new system or
end of job), page 29.
2. Follow Pressure Relief Procedure, page 22.
3. Ensure handle (312) is in the down position.
Remove the screws (313), jam nut (304), handles
(311), handle rod (312), clips (318), and
springs (320).
311
Fluid Circulation Manifold with Over Pressure Relief Valves
See FIG. 11.
1. Flush before repairing equipment, if possible. See
Empty and Flush Entire System (new system or
end of job), page 29.
2. Follow Pressure Relief Procedure, page 22.
3. Disconnect all fluid hoses from the fluid circulation
manifold (35).
4. Remove the mix manifold if it is assembled to the
fluid circulation manifold. See Mix Manifold
Assembly for instructions.
5. Loosen the two screws (37) that secure the manifold
(35) to the cart (1).
6. Remove the two screws (37) and fluid circulation
manifold (35) from the cart (1).
313
302
304
320
318
302
4. Unscrew both over pressure relief valves (302) from
the manifold.
NOTE: The correct over pressure relief valve must be
used on all systems. Choose the correct color coded
valve from the chart on page 39.
5. Apply blue threadlock to new over pressure relief
valves (302) and install in the manifold. Torque to
28-32 ft-lb (38-43 N•m).
312
311
313
302
304
320
318
r_258988_3a0420a_2b
6. Place a spring (320) over each valve stem. Place a
clip (318) in each valve stem groove to retain the
springs.
38 3A0420T
Repair
7. Slide handle (311) onto valve stem and rotate
approximately 90° until you feel it fully lock against
the valve seat. Repeat for opposite side.
8. Remove handle then place handle (311) on valve
stem (302) at the vertical, or near vertical, position.
9. Apply blue threadlock on the nut (304) threads and
tighten the handle against the spring (320) and
clip (318). Torque to 70-80 in-lb (7.9-9 N•m).
10. Place the rod (312) and the second handle (311) on
second valve stem aligned with the opposite handle.
11. Repeat step 9.
Fluid Circulation Manifold Replacement Guide
Colored Valve Sleeve
12. Install two screws (313) in handles (311).
13. Check operation of the handle and valves.
14. Operate the handle in and out of the spray and circulate positions.
15. Check for clearance with fittings.
NOTE:
• Both valves should settle firmly into the spray
position inward against the seats in the valve.
• Both valve stems should rotate out to their most
extended positions when the handle is pulled
down to the circulate position.
ti19169a
ti19168a
Circulation
Manifold (35)
Part No.
Relief
Valve (302)
Part No.
Valve Sleeve
Color
Target Opening
Pressure
psi (MPa, bar) Use with:
All XP35 models,
262784 262808 Purple 5300 (37, 365)
XP-h models 284101,
284201, 284301, 284401
All XP50 models,
262783 262809 Gold 7100 (49, 490)
XP-h models 284102,
284202, 284302, 284402
All XP70 models,
262806 262520 Silver 9250 (64, 638)
XP-h models 284103,
284203, 284303, 284403
NOTE: Original XP70 valves did not include a silver valve sleeve. When replacing these original valves, replace with
the current valves that have the silver valve sleeve.
3A0420T 39
Repair
Hoppers
1. If material is in the hopper pump out the remaining
material.
2. If the pump has failed:
a. Place a waste container beneath the plug on fit-
ting (61). Remove the plug.
b. Drain all material from hopper into the waste
container.
c. Install plug after material is no longer draining
from fitting (61).
r_571101_3a0420a_41a
Optional Solvent Pump
1. Follow Pressure Relief Procedure, page 22.
2. Disconnect the fluid line and air lines from the solvent pump.
3. Loosen the four screws that attach the solvent pump
to the cart (1). Lift and pull pump from the slots.
1
plug
3. Follow Pressure Relief Procedure, page 22.
4. Loosen fitting (61) and disconnect hopper from
pump.
5. Remove the recirculation line from the hopper and
place in a waste container.
6. Lift the hopper off of the mounting bracket.
61
U
r_571101_3a0420a_18a
screw
4. Refer to the Merkur Pump Assembly manual to service or repair the solvent pump.
5. Follow the steps in reverse order to reinstall the solvent pump.
7. Repeat for second hopper.
40 3A0420T
Optional Fluid Heaters
NOTE: Wiring for heaters is not provided. See the Vis-
con HP heater manual for wiring, repair, and parts information for explosion-proof heaters.
Service and Repair
1. Follow Pressure Relief Procedure, page 22.
2. Disconnect the fluid lines and electrical wiring from
the fluid heater.
3. Refer to the Viscon HP heater manual to service or
repair. Refer to the heater adapter kit manual
406861 for installation instructions.
4. Reconnect the fluid lines and electrical wiring.
Replace
Repair
1. Follow steps 1 through 2 in the Fluid Heaters Service and Repair section.
2. Loosen the four mounting screws, lock washers,
and plain washers on back of the heater. Slide the
heater up and remove from the cart.
3. Replace the heater. Follow the steps in reverse
order to install a new heater.
r_571101_3a0420a_42a
3A0420T 41
Parts
Parts
Cart-Mounted System
1. Apply anaerobic pipe sealant to all non-swiveling pipe threads.
64
17
15
38
11
10
17
14
11
54
2
1
12
13
r_571101_3a0420a_30a
5
18
8
9
13
16
3
13
50
53
52
7
42 3A0420T
r_571101_3a0420a_30a
Cart-Mounted System Continued
Parts
18
5
22
24
48
r_571101_3a0420a_44a-1
Standard Mix Manifold Models
41
35
37
36
32
27, 28
32
27, 28
27, 28
52
25
26
29
30
31
4
23
22
24
24
5
6
r_571101_3a0420a_45a
49 “A”
56
90
1
49 “B”
89
70
69
18
61
51
66
55
59
62
58
60
57
65 (inside hopper)
TI17434a
3A0420T 43
Parts
Cart-Mounted System Continued
35
Quickset Mix Manifold Models
36
30
31
TI19233a
44 3A0420T
Parts Common to All Systems
Ref Part Description Qty
1 258913 CART, weldment
2 262476 AXLE
3 111841 WASHER, plain 5/8
6 100101 SCREW, cap, hex head
7 113362 WHEEL, semi-pneumatic
8 154628 WASHER
9 113436 RING, retaining
10 124410 BEARING, sleeve, 1.00 x 1.25 x
1.5
11 124664 WASHER, 1 in. ID, stainless
steel
12 15A913 AXLE
13 191824 WASHER, space
14 113807 WHEEL, flat free, urethane
15 258982 HANDLE, cart
16 101242 RING, retaining, ext.
17 258983 MODULE, air controls, inlet
19 16F206 LABEL, handles
21 111218 CAP, tube, square
24 H75003 HOSE, coupled, 7250 psi,
0.50 ID, 3 ft
37 106212 SCREW, cap, hex head
38 116139 GRIP, handle
47 206995 FLUID, TSL, 1 qt.
49 15U654 LABEL, identification, A/B
50 555357 SCREW
53 124259 BRAKE, plunger clamp
54 124291 PIN, spring
58 116704 ADAPTER, 9/16-18 JIC x 1/4 npt
59 15V421 TUBE, recirculation
67 16E336 GUIDE, quick start
69 16F615 TOOL, wrench, Xtreme
70▲ 16F359 LABEL, warning, fire and explo-
sion hazard
71 16F536 LABEL, arrow
89 16G819 TOOL, wrench, Xtreme, filter
91 126786 TOOL, wrench, restrictor valve
Parts
1
1
2
4
2
2
2
1
2
1
4
2
1
2
1
1
4
2
2
2
1
1
4
1
2
2
2
1
1
1
2
1
1
▲ Replacement Danger and Warning labels, tags, and
cards are available at no cost.
3A0420T 45
Parts
Parts Varying By Model - XP35 Systems
Quantity (By System)
Ref Part Description
262804
281000
281101
281102
281105
281106
281201
281202
281205
281206
281252
281255
281256
281301
281302
281305
281306
281401
281402
281405
4 281100 PUMP PACKAGE, fixed ratio, 1.0:1 1 1 1 1
281200 PUMP PACKAGE, fixed ratio, 2.0:1 1 1 1 1
262803 PUMP PACKAGE, fixed ratio, 2.5:1 1 1 1 1
281300 PUMP PACKAGE, fixed ratio, 3.0:1 1 1 1 1
281400 PUMP PACKAGE, fixed ratio, 4.0:1 1 1 1 1
24M422 PUMP PACKAGE, no lowers 1
5 100133 WASHER, lock, 3/8 7 7 71171171171111711711711711711
18 100131NUT, full hex 333737373773737373737
20 512519 MIXER, 1/2-12 element 3 3 3 3 3 3 3 3 3 3 3
22 158491FITTING, nipple 444444444444444444444
23 15M987FITTING, elbow, 60 degree 222222222222222222222
25 H43825 HOSE, coupled, 4500 psi, 0.375 ID, 25 ft 1 1 1 1 1 1 1 1 1 1 1
26 15B729 COUPLING 1 1 1 1 1 1 1 1 1 1 1
27 262478 HOUSING, mixer 3 3 3 3 3 3 3 3 3 3 3
28 248927 KIT, mixer element, 25 pack 1 1 1 1 1 1 1 1 1 1 1
29 150287 COUPLING 1 1 1 1 1 1 1 1 1 1 1
30 H42510 HOSE, coupled, 4500 psi, 0.25 ID, 10 ft 1 1 1 1 1 1 1 1 1 1 1
31 XTR504 GUN, XTR5 1 1 1 1 1 1 1 1 1 1 1
32 162024 COUPLING 2 2 2 2 2 2 2 2 2 2 2
35 262784 MANIFOLD, recirculation, 1/2 valves 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
36 262807 MANIFOLD, mix, 1/2 valves 1 1 1 1 1 1 1 1 1 1 1
41 158683FITTING, elbow, 90 degree 222222222222222222222
48 101566 NUT, lock 2 2 2 2 2 2 2 2 2 2 2
51 124450 CLAMP, spring, constant-tension 2 2 2 2 2 2 2 2 2 2
52 124293 BOLT, u-bolt, 3/8-16, 1.00 dia 1 1 1 1 1 1 1 1 1 1 1
55 24E872 BRACKET, hopper 2 2 2 2 2 2 2 2 2 2
56 262479 HOPPER, blue 1 1 1 1 1 1 1 1 1 1
57 262480 HOPPER, green 1 1 1 1 1 1 1 1 1 1
60 H52506 HOSE, coupled, 5600 psi, 0.25 ID, 6 ft 2 2 2 2 2 2 2 2 2 2
H52510 HOSE, coupled, 5600 psi, 0.25 ID, 10 ft 2 2 2 2 2 2 2 2 2 2 2
61 16D376 FITTING, swivel, 1-1/4, with plug 2 2 2 2 2 2 2 2 2 2
62 111192 SCREW, cap flange head 4 4 4 4 4 4 4 4 4 4
64 103347 VALVE, safety, 100 psi 1 1 1 1
113498 VALVE, safety, 110 psi 1 1 1 1 1
114055 VALVE, safety, 105 psi 1 1 1 1 1 1 1 1
16M190 VALVE, safety, 95 psi 1 1 1 1
65 262482 STRAINER, hopper, 7 gallon 2 2 2 2 2 2 2 2 2 2
66▲ 15T468 LABEL, warning 2 2 2 2 2 2 2 2 2 2
68 114958 STRAP, tie 101010101010101010101010101010101010101010
90 16J688 PLUG, hole, gauge 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
281406
▲ Replacement Danger and Warning labels, tags, and
cards are available at no cost.
46 3A0420T
Parts Varying By Model - 282xxx (XP50) Systems
Parts
Quantity (By System)
Ref Part Description
4 282100 PUMP PACKAGE, fixed ratio, 1.0:1
282150 PUMP PACKAGE, fixed ratio, 1.5:1
282200 PUMP PACKAGE, fixed ratio, 2.0:1
282250 PUMP PACKAGE, fixed ratio, 2.5:1
282300 PUMP PACKAGE, fixed ratio, 3.0:1
282330 PUMP PACKAGE, fixed ratio, 3.3:1
282400 PUMP PACKAGE, fixed ratio, 4.0:1
24M423 PUMP PACKAGE, no lowers
5 100133 WASHER, lock, 3/8
18 100131 NUT, full hex
20 512519 MIXER, 1/2-12 element
22 158491 FITTING, nipple
23 15M987 FITTING, elbow, 60 degree
25 H53825 HOSE, coupled, 5600 psi, 0.375 ID,
25 ft
26 15B729 COUPLING
27 262478 HOUSING, mixer
28 248927 KIT, mixer element, 25 pack
29 150287 COUPLING
31 XTR504 GUN, XTR5
32 162024 COUPLING
35 262783 MANIFOLD, recirculation, 1/2 valves
36 262807 MANIFOLD, mix, 1/2 valves
41 158683 FITTING, elbow, 90 degree
48 101566 NUT, lock
51 124450 CLAMP, spring, constant-tension
52 124293 BOLT, u-bolt, 3/8-16, 1.00 dia
55 24E872 BRACKET, hopper
56 262479 HOPPER, blue
57 262480 HOPPER, green
60 H52506 HOSE, coupled, 5600 psi, 0.25 ID, 6 ft
H52510 HOSE, coupled, 5600 psi, 0.25 ID,
10 ft
61 16D376 FITTING, swivel, 1-1/4, with plug
62 111192 SCREW, cap flange head
64 103347 VALVE, safety, 100 psi
113498 VALVE, safety, 110 psi
114055 VALVE, safety, 105 psi
65 262482 STRAINER, hopper, 7 gallon
66▲ 15T468 LABEL, warning
68 114958 STRAP, tie
90 16J688 PLUG, hole, gauge
282000
282101
282102
282105
282106
282151
282152
282155
282156
282201
282202
282205
282206
282251
282252
282255
282256
282301
282302
282305
282306
282331
282332
282401
282402
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1
1
7 711711711711711711711711711711711711711
337373737373737373737373737
3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
444444444444444444444444444
222222222222222222222222222
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
3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
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 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
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 1 1 1 1 1 1
222222222222222222222222222
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
2 2 2 2 2 2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2 2
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 2 2 2 2 2 2 2 2 2 2 2
3 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 3 1 2
2 2 2 2 2 2 2 2 2 2 2 2 2
4 4 4 4 4 4 4 4 4 4 4 4 4
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 2 2 2 2 2 2 2 2 2 2 2
2 2 2 2 2 2 2 2 2 2 2 2 2
101010101010101010101010101010101010101010101010101010
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
282405
1 1 1 1
282406
▲ Replacement Danger and Warning labels, tags, and
cards are available at no cost.
3A0420T 47
Parts
Parts Varying By Model - 283xxx (XP50 Quickset) Systems
Quantity (By System)
Ref Part Description
283101
283102
283201
283202
283301
283302
283401
283402
4 282100 PUMP PACKAGE, fixed ratio, 1.0:1 1 1
282200 PUMP PACKAGE, fixed ratio, 2.0:1 1 1
282300 PUMP PACKAGE, fixed ratio, 3.0:1 1 1
282400 PUMP PACKAGE, fixed ratio, 4.0:1 1 1
5 100133 WASHER, lock, 3/8 7 11 7 11 7 11 7 11
18100131NUT, full hex 37373737
22158491FITTING, nipple 44444444
2315M987FITTING, elbow, 60 degree 22222222
28 248927 KIT, mixer element, 25 pack 1 1 1 1 1 1 1 1
31 248844 GUN, Flex 1 1 1 1 1 1 1 1
32 162024 COUPLING 1 1 1 1 1 1 1 1
35 262783 MANIFOLD, recirculation, 1/2 valves 1 1 1 1 1 1 1 1
36 24M398 MANIFOLD, Quickset 1 1 1 1 1 1 1 1
41158683FITTING, elbow, 90 degree 22222222
51 124450 CLAMP, spring, constant-tension 2 2 2 2
55 24E872 BRACKET, hopper 2 2 2 2
56 262479 HOPPER, blue 1 1 1 1
57 262480 HOPPER, green 1 1 1 1
60 H52506 HOSE, coupled, 5600 psi, 0.25 ID, 6 ft 2 2 2 2
H52510 HOSE, coupled, 5600 psi, 0.25 ID, 10 ft 3 1 3 1 3 1 3 1
61 16D376 FITTING, swivel, 1-1/4, with plug 2 2 2 2
62 111192 SCREW, cap flange head 4 4 4 4
64 113498 VALVE, safety, 110 psi 1 1 1 1 1 1 1 1
65 262482 STRAINER, hopper, 7 gallon 2 2 2 2
66▲ 15T468 LABEL, warning 2 2 2 2
68114958STRAP, tie 1010101010101010
90 16J688 PLUG, hole, gauge 1 1 1 1 1 1 1 1
▲ Replacement Danger and Warning labels, tags, and
cards are available at no cost.
48 3A0420T
Parts Varying By Model - XP70 Systems
Parts
Quantity (By System)
Ref Part Description
571000
571101
571102
571151
571152
571201
571202
571251
571252
571301
571302
571401
4 571100 PUMP PACKAGE, fixed ratio, 1.0:1 1 1
571150 PUMP PACKAGE, fixed ratio, 1.5:1 1 1
571200 PUMP PACKAGE, fixed ratio, 2.0:1 1 1
571250 PUMP PACKAGE, fixed ratio, 2.5:1 1 1
571300 PUMP PACKAGE, fixed ratio, 3.0:1 1 1
571400 PUMP PACKAGE, fixed ratio, 4.0:1 1 1
24M423 PUMP PACKAGE, no lowers 1
5 100133 WASHER, lock, 3/8 7 7 11 7 11 7 11 7 11 7 11 7 11
18100131NUT, full hex 3373737373737
20 512519 MIXER, 1/2-12 element 3 3 3 3 3 3 3 3 3 3 3 3 3
22158491FITTING, nipple 4444444444444
23 15M987 FITTING, elbow, 60 degree 2 2 2 2 2 2 2 2 2 2 2 2 2
25 H73825 HOSE, coupled, 7250 psi, 0.375 ID, 25 ft 1 1 1 1 1 1 1 1 1 1 1 1 1
26 15B729 COUPLING 1 1 1 1 1 1 1 1 1 1 1 1 1
27 262478 HOUSING, mixer 3 3 3 3 3 3 3 3 3 3 3 3 3
28 248927 KIT, mixer element, 25 pack 1 1 1 1 1 1 1 1 1 1 1 1 1
29 150287 COUPLING 1 1 1 1 1 1 1 1 1 1 1 1 1
30 H72510 HOSE, coupled, 7250 psi, 0.25 ID, 10 ft 1 1 1 1 1 1 1 1 1 1 1 1 1
31 XTR704 GUN, XTR7 1 1 1 1 1 1 1 1 1 1 1 1 1
32 162024 COUPLING 2 2 2 2 2 2 2 2 2 2 2 2 2
35 262806 MANIFOLD, recirculation, 1/2 valves 1 1 1 1 1 1 1 1 1 1 1 1 1
36 262807 MANIFOLD, mix, 1/2 valves 1 1 1 1 1 1 1 1 1 1 1 1 1
41 158683 FITTING, elbow, 90 degree 2 2 2 2 2 2 2 2 2 2 2 2 2
48 101566 NUT, lock 2 2 2 2 2 2 2 2 2 2 2 2 2
51 124450 CLAMP, spring, constant-tension 2 2 2 2 2 2
52 124293 BOLT, u-bolt, 3/8-16, 1.00 dia 1 1 1 1 1 1 1 1 1 1 1 1 1
55 24E872 BRACKET, hopper 2 2 2 2 2 2
56 262479 HOPPER, blue 1 1 1 1 1 1
57 262480 HOPPER, green 1 1 1 1 1 1
60 H52506 HOSE, coupled, 5600 psi, 0.25 ID, 6 ft 2 2 2 2 2 2
H52510 HOSE, coupled, 5600 psi, 0.25 ID, 10 ft 2 2 2 2 2 2 2
61 16D376 FITTING, swivel, 1-1/4, with plug 2 2 2 2 2 2
62 111192 SCREW, cap flange head 4 4 4 4 4 4
64 113498 VALVE, safety, 110 psi 1 1 1 1 1 1 1 1 1 1 1
116643 VALVE, safety, relief, air, 90 psi 1 1
65 262482 STRAINER, hopper, 7 gallon 2 2 2 2 2 2
66▲ 15T468 LABEL, warning 2 2 2 2 2 2
68 114958 STRAP, tie 10101010101010101010101010
90 16J688 PLUG, hole, gauge 1 1 1 1 1 1 1 1 1 1 1 1 1
571402
▲ Replacement Danger and Warning labels, tags, and
cards are available at no cost.
3A0420T 49
Parts
Bare Proportioning Pump Package
103
2 3
123
128
121
101
104
Model 571100 shown
109
102
110
137
136
129
133
134
3
3 6
1
7
122
101
138
7
106
1
105
1
4
135
139
122
107
108
1
111
113
5
131
116
112
119
116
130
120
130
r_258914_3A0420A_2a
1
Torque together to 50-60 ft-lb (68-81 N•m).
2
Torque to 145-155 ft-lb (196-210 N•m).
3
Apply blue thread sealant.
4
Insert lanyard from locking pin onto pumps (17, 18) as shown.
5
Do not apply lubricant.
6
Torque to 70-80 ft-lb (95-108 N•m).
7
Apply lithium grease to mating tapered surfaces.
140
117
117 or 118
108
1
r_258914_3A0420A_3a
50 3A0420T
Parts
Parts Common to All Pump Packages
Ref Part Description Qty
101 262465 PLATE, motor 1
105 262468 ROD, tie, 14.25 long, with shoulder 4
106 262469 ROD, tie, 14.25 long, 1.25 dia 2
107 154636 WASHER, flat 3
108 101712 NUT, lock, 5/8-11 9
109 16D451 NUT, yoke 1
110 262470 BRACKET, ratio indicator 1
111 262471 YOKE, pump assembly 1
112 15H392 ROD, adapter Xtreme 2
113 262472 SLEEVE, with bearing 2
Ref Part Description Qty
116 123976 RING, snap, external 2
122 262474 COVER, pump 2
128❄ 15J277 CONTROL, de-ice 1
130 124078 CLAMP, spring, constant-tension 2
134 262475 BRACKET, ratio indicator 1
135 16E882 STRAP, lowers 2
136 --- SCREW, cap, button head, 10-32 8
137 124172 WASHER, retaining, nylon, 10-32 8
138 124665 NUT, captive, 10-32 4
139▲ 15T468 LABEL, warning 2
▲ Replacement Danger and Warning labels, tags, and cards are available at
no cost.
❄
Kit NXT102 (de-ice knob 5-pack) also available.
Parts Varying by Pump Package
Quantity (By Pump Package)
Ref Part Description
102 262466 ROD, tie, 4.00 long 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
16M882 ROD, tie, 5.00 long 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
103 24M394 MOTOR, hydraulic 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
N34DN0 MOTOR, 3400, de-icing 1 1 1 1 1 1
N65DN0 MOTOR, 6500,de-icing 1 1 1 1 1 1 1 1 1 1 1 1 1 1
104 262467 ROD, adapter 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
16M654 ADAPTER, motor 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
117 L085C0 PUMP LOWER, 85cc 1
L090C0 PUMP LOWER, 90cc 2 1 2 1 2
L115C0 PUMP LOWER, 115cc 1 1 1 1
L14AC0 PUMP LOWER, 145cc 1 1 1 2 1 2 1 1 1 1 1 1 1
L18AC0 PUMP LOWER, 180cc 1 1 1 1 1
L22AC0 PUMP LOWER, 220cc 1 1 2 1 1
L29AC0 PUMP LOWER, 290cc 1 1 1 1
118 L036C0❖ PUMP LOWER, 36cc 1 1 1
L048C0❖ PUMP LOWER, 48cc 1 1 1
L054C0❖ PUMP LOWER, 54cc 1 1 1 1
L058C0❖ PUMP LOWER, 58cc 1 1 1 1 1 1 1
L072C0❖ PUMP LOWER, 72cc 1 1 1 1
L097C0 PUMP LOWER, 97cc 1 1
119† 244819 COUPLING, for
145-290cc pump lower
247167 COUPLING, for
36-115cc pump lower
121 262473 COVER, motor rod 1 1 1 1 1 1 1 1 1 1 1 1 1 1
262704 COVER, motor rod 1 1 1 1 1 1
262734 COVER, motor rod 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
123 --- LABEL, identification 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
129 16D029 LABEL, XP70 1 1 1 1 1 1
16M178 LABEL, XP50 1 1 1 1 1 1 1
16M179 LABEL, XP35 1 1 1 1 1 1
131▲ 15H108 LABEL, pinch point 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1
133 114225 TRIM, edge protection 1.32.1 1.31.3 1.3 1.3 1.3 2.1 2.1 2.1 2.1 2.1 2.1 2.12.1 2.12.1 2.1 2.11.3 2.1 2.1 2.12.1 2.11.3 2.1 2.1 1.3 2.1 2.1 2.12.1 2.12.1
140 238909 WIRE, grounding 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
244524 WIRE, grounding 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
141◆ 16N396 LABEL, XP-h 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
142▲ ◆16N375 LABEL, warning, multi-
lingual
198◆ 206995 FLUID, tsl, 1 qt. 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
199◆ 16F615 TOOL, wrench, Xtreme 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
262803
281100
281200
281300
281400
282100
282150
282200
282250
282300
282330
282400
284101
284102
284103
284201
284202
284203
284251
284252
284253
284301
284302
284303
284401
284402
284403
24M422
24M423
1 1 1 2 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1
1 2 2 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
571100
571150
571200
571250
571300
571400
▲ Replacement Danger and Warning labels, tags, and cards are available at
no cost.
❖ Includes rupture disc 258962.
† Included with new pump assemblies (117, 118).
◆ Not shown.
3A0420T 51
Parts
Air Controls, 258983
201
2
211
206
214
207
Air Flow
216
215
208
211
213
204
Air Flow
209
210
203
209
206
214
202
205
TI17433a
1. Apply anaerobic pipe sealant to all non-swiveling pipe threads.
2
Connect hose (214) to fitting (206) and air distribution manifold (213).
Qty
Ref. No. Part No. Description
201 16F014 REGULATOR, air, T-handle 1
202 207675 MANIFOLD, air 1
203 113218 VALVE, ball 1
204 100509 PLUG; 1/4 npt 1
205 100403 PLUG; 1/8 npt 1
206 160327 FITTING, union, 90°; 3/4 male x
female
207 101689 GAUGE, pressure, air 1
208 155699 FITTING, elbow, street; 3/8 npt 3
209 119992 FITTING, pipe, nipple, 3/4 x
3/4 npt
210 117628 FITLTER, air, auto drain; 3/4 npt 1
210a✖ 106204 ELEMENT, filter; 3/4 npt 1
r_571100_3A0420A_1a-1
Ref. No. Part No. Description
.
211 157785 FITTING, union; 3/4 male x
female
213 15E145 MANIFOLD, air distribution 1
214 16E004 HOSE, coupled, air; 26 in.
(660 mm)
215 157350 NIPPLE; 3/8 x 1/4 npt 3
2
216 115781 CAP PLUG; 1/4 npt 3
✖ Not shown.
2
Qty
.
2
1
52 3A0420T
Fluid Circulation Manifold with Over Pressure Relief Valve
Assembly 262784 (XP35); 262783 (XP50); 262806 (XP70)
Parts
313
311
318
320
304
6
2 3
302
4
5
305
317
301
307
1. Apply anaerobic pipe sealant to all non-swiveling pipe
threads.
2
Torque to 28-32 ft-lb (38-43 N•m).
3
Apply blue anaerobic adhesive to threads.
312
308
310
309
308
308
309
303
320
5
318
317
305
302
2 3 4
316
r_258988_3a0420a_1c
4
Further tighten either valve (302) as required to line
up handle straight across.
5
Apply grease to spring ends.
6
Torque to 70-90 in-lb (7.9-9 N•m).
313
311
304
336
Ref Part Description Qty
301 16D693 BLOCK, manifold, recirculation 1
302† 262520 VALVE, over pressure relief, silver,
XP70
◆ 262809 VALVE, over pressure relief, gold,
XP50
★ 262808 VALVE, over pressure relief, purple,
XP35
303 156684 UNION; 1/2 in. male x female 2
304 112309 NUT, hex, jam 2
305 198241 PLUG, port, pressure; 11/16-24 2
307†◆ 114434 GAUGE, pressure, fluid, sst; 10k psi 2
★ 113654 GAUGE, pressure, fluid, sst; 5k psi 2
308 100840 FITTING, elbow, street; 1/4 npt 4
309 156971 FITTING, nipple; 1/4 npt x npsm 2
310 557349 PLUG, dry seal 1/8 npt 2
311 16E334 HANDLE, manifold 2
312 16E332 ROD, connecting, handle 1
Ref Part Description Qty
316 156684 FITTING, nipple, 1/2 npt x 1/2 npt 2
317 121399 O-RING, solvent resistant 2
2
318 124676 RING, snap, external 2
320 150829 SPRING, compression 2
2
351✖ 159239 FITTING, nipple, pipe, reducing 2
352✖ 156173 UNION, swivel 2
2
✖ Not shown. Shipped loose.
★ For XP35 systems only.
◆ For XP50 systems only.
† For XP70 systems only.
NOTE: Loose fittings are supplied with replacement
manifold to also fit Series A XP Proportioners with
3/8 in. mix manifold ball valves.
313 124859 SCREW, button head 2
3A0420T 53
Recommended Spare Parts
Recommended Spare Parts
Keep these spare parts on hand to reduce downtime.
Pump Repair Kits
See page 13 to see what pumps are used on your system. See lower manual for repair kits.
Pump Filter O-rings (packs of 10)
262483, Top o-ring
244895, Middle o-ring
262484, Bottom o-ring
Recirculation/Overpressure valve (see
page 39)
XP35: 262808, purple
(also for use with XP-h 284x01 assemblies)
XP50: 262809, gold
(also for use with XP-h 284x02 assemblies)
XP70: 262520, silver
(also for use with XP-h 284x03 assemblies)
15K692, Seal Mix Manifold Check Valve
Cartridge
NOTE: 15K692 must be replaced when cleaning the
check valves.
1/2 in. Mix Manifold Inlet Ball Valves
24M601, Ball valve repair kit
262740, Spare valve (no handle)
262739, Spare valve (single handle)
248927, Spare Mix Elements (pack of 25)
1/2 in. OD x 12 element, acetal plastic
248837, XTR Spray Gun Repair Kit
XHD010, Seat/Seal Kit for XHD RAC Tips
(5 pack)
XHDxxx, spray tips
See spray gun manual for tips.
54 3A0420T
Accessories and Kits
Accessories and Kits
Acceptable For Use in Explosive Atmospheres
Blue 7 Gallon Hopper Kit, 24F376
Green 7 Gallon Hopper Kit, 24F377
Mount to the sides of the XP system. See manual
406860 for more information.
Solvent Pump Kit, 262393
For supplying solvent to the mix manifold. See manual
310863 for more information.
Desiccant Dryer Kit, 262454
For use with polyurethane isocyanates in 7 gallon hoppers. See manual 406739 for more information.
Desiccant Dryer Filter 2 Pack, 24K984
Heater Adapter Kit, 262450
Hose and fittings for connecting Viscon HP heaters to
XP system. See manual 406861 for parts. Purchase
heaters separately, see heater manual for part numbers.
Twistork Agitator Kit, 256274
For mixing viscous materials held within a 55 gallon
drum. See manual 312769 for more information.
20 Gallon Hopper Kit, 255963
Floor Stand for 20 Gal. Hopper, 262824
1-1/2 in. ID Hose Flex Feed Kit, 262820
XP Wall Mount Bracket, 262812
Works with air or hydraulic XP systems.
Leg Stand, 24M281
Includes wall bracket 262812.
1/2 in. Ball Valve Upgrade Kit for Mix
Manifold, 24M593
Quickset Mix Manifold, 24M398
Mix manifold with independent A and B flushing for use
with quick hardening materials. See mix manifold manual 3A0590 for more information.
Remote Mix Manifold Carriage, 262522
A protective guard to mount mix manifold remote. See
mix manifold manual 3A0590 for more information.
Mix Manifold Restrictor Wrench, 126786
Gun Splitter with Carriage, 262826
5:1 Feed Pump Kit, 256276
For supplying viscous materials from a drum to XP
system. See manual 312769 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 55 gallon
drum to XP system. See manual 312769 for more
information.
One splitter valve to use one, two, or three spray guns
with the system. Provides independent flush for two
guns. Optional 3rd gun port does not have independent
flush. See manual 3A2573 for more information.
DataTrak™ Conversion Kit, NXT606
Intrinsically safe battery operated NXT air motor accessory for material tracking system diagnostics and runaway control. See manual 311486 for more information.
10:1 Drum Feed Kit, 256433
For supplying highly viscous material from a 55 gallon
drum to XP system. See manual 312769 for more information.
3A0420T 55
Accessories and Kits
Not Approved For Explosive Atmospheres
These kits do not carry the EX mark.
2:1 Feed Pump Kit, 256275
For supplying viscous materials from a drum to XP system. See manual 312769 for more information.
2:1 Drum Feed Kit, 256232
One T2 pump feed kit and one Twistork agitator kit for
mixing and supplying viscous materials from a 55 gallon
drum to XP system. See manual 312769 for more information.
Wall Powered Pressure Monitor Kit, 262940
Air Powered Pressure Monitor Kit, 262942
Automatically monitors difference between A and B
pressures when at spray pressure and shuts down the
system if there is a problem.
56 3A0420T
Technical Data
Technical Data
XP Proportioners
U.S. Metric
Maximum Fluid Working Pressure See Models section beginning on page 11.
Maximum Air/Hydraulic Oil Working Pressure See Models section beginning on page 11.
Combined Fluid Output (cc/cycle) See Models section beginning on page 11.
Pressure Ratio See Models section beginning on page 11.
Fluid Flow at 40 cpm See Models section beginning on page 11.
Hydraulic Fluid Consumption (XP-h models only) 0.2 gallons per cycle 0.76 liters per cycle
Air inlet size 3/4 npsm(f)
Maximum air pressure supply to the system 175 psi 12 bar, 1 MPa
Fluid pump inlets without hoppers 1-1/4 in. npsm(m)
Fluid gauge manifold outlets 1/2 in. npt(f)
Fluid mix manifold inlets 1/2 in. npt(f) ball valves
Mix manifold material outlet 1/2 in. npt(f)
Maximum feed pressure from remote source 250 psi 17 bar, 1.7 MPa
Sound pressure 86 dBA at 100 psi (7 bar, 0.7 MPa)
Sound power 98 dBA at 100 psi (7 bar, 0.7 MPa)
Maximum Storage Time 5 years (To maintain original performance, replace soft
seals after 5 years of inactivity.)
Maximum Lifetime Indefinite with recommended maintenance and periodic
rebuilds for critical parts.
Power Efficiency Factor (XP70) 75 cu. ft compressed air/1 gallon sprayed material at 100 psi
3
2.12 m
(0.7 MPa)
Air consumption per 1 gallon (3.78 l) of flow
XP70
XP50
XP35
Filtration:
Air inlet filtration 40-micron filter/separator included
XP pump outlets 30 mesh
XTR Spray Gun 60 mesh
Fluid Viscosity Range:
Gravity feed with 7 gallon (26 liter) hoppers 200 to 20,000 cps (pourable)
Pressure feed Any viscosity that will not require feed pressure more than
Environmental Rating (Indoor/outdoor)
Hazardous Areas EX II 2 G c IIA T2
Ambient Temperature Range:
Operating 40-130°F 4-54°C
Storage 30-160°F -1-71°C
Maximum Fluid Temperature 160°F 71°C
Wetted materials:
Housings and manifolds Carbon steel with electroless nickel plating
Miscellaneous parts Plated carbon steel, stainless steels, carbide, acetal, UHM-
Pump packings Carbon filled PTFE, proprietary UHMWPE
Flush pump suction tube Aluminum
Hoses Nylon core
75 scfm at 100 psi/gpm (2.12 m
60 scfm at 100 psi/gpm (1.7 m
50 scfm at 100 psi/gpm (1.42 m
15% of outlet pressure
NOTE: XP-h pump packages (284xxx) are not Ex rated.
WPE, nylon, PTFE solvent resistant plastics
compressed air/1 liter sprayed material at 7 bar
3
/min at 7 bar, 0.7 MPa)
3
/min at 7 bar, 0.7 MPa)
3
/min at 7 bar, 0.7 MPa)
3A0420T 57
Dimensions
Weight:
Full XP35, XP50, or XP70 System with heaters, solvent
flush pump, and hoppers
Bare XP35, XP50, or XP70 system with no heaters, solvent
flush pump, or hoppers
XP35, XP50, or XP70 Pump only 286 lb 130 kg
XP-h System 290 lb 132 kg
575 lb 261 kg
425 lb 193 kg
Dimensions
Top View
Full SystemBare System
(813 mm)
Side View
32 in.
52 in.
(1321 mm)
35 in.
(889 mm)
r_571100_3a0420_100a
60 in.
(1524 mm)
r_571100_3a0420_101a
58 3A0420T
Floor Mounting Dimensions, Top View
32 in.
(812.8 mm)
Dimensions
22 in.
(558.8 mm)
6.75 in.
(171.45 mm)
16.90 in.
(429.26 mm)
15.25 in.
(387.35 mm)
40 in.
(1016 mm)
3A0420T 59
Dimensions
Bare Proportioner Mounting Hole Dimensions
The dimensions below is the minimum opening size for mounting a bare proportioner.
10.125 in.
(257.175 mm)
3/8-16 (4x)
10.375 in.
(263.525 mm)
4.05 in.
(102.87 mm)
120° (4x)
150° (4x)
0.25 in.
(6.35 mm)
(95.25 mm)
5.06 in.
(128.52 mm)
2.25 in.
(57.15 mm)
9.25 in.
(234.95 mm)
3.75 in.
7.5 in.
(190.5 mm)
14.35 in.
(364.49 mm)
60 3A0420T
Wall Mount Bracket 262812 Dimensions
15.0 in.
(381 mm)
11.8 in.
(300 mm)
9.75 in.
(248 mm)
Dimensions
17.9 in.
(455 mm)
18.4 in.
(467 mm)
ti19046a
3A0420T 61
Dimensions
Floor Stand 24M281 Dimensions
21.2 in.
(538 mm)
30.3 in.
(770 mm)
Hydraulic Unit Dimensions
17.8 in.
(451 mm)
32.7 in.
(829 mm)
ti19047a
30.3 in.
(770 mm)
Shown installed on floor stand
53 in.
(1346 mm)
ti19048a
17.8 in.
(451 mm)
62 3A0420T
Dimensions
3A0420T 63
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 reconnaissen
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.
t avoir convenu que la
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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original instructions.
This manual contains English. MM 3A0420
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
Revision T, April 2014
Loading...