Graco 3A2989G User Manual

Repair - Parts

XM PFP

For spraying two-component intumescent epoxies. For professional use only. Not for use in explosive atmospheres or hazardous locations.

Important Safety Instructions

Read all warnings and instructions in all supplied manuals. Save all instructions.

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

3A2989G

WLD

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

Keep Components A and B Separate . . . . . . . . 6

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 6

Components A and B . . . . . . . . . . . . . . . . . . . . . 6

Component Identification . . . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Replace Air Filter Element . . . . . . . . . . . . . . . . . 9

User Interface/Control Box . . . . . . . . . . . . . . . . 10

Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Dosing Valve Assembly . . . . . . . . . . . . . . . . . . 19

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Pump Assembly (System Module) . . . . . . . . . . 21

Pail Feed RAM Pump Assembly (Feed Module) 22

Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Replace Radar Level Sensor . . . . . . . . . . . . . . 24

Set Up a New Guided Radar Level Sensor . . . 25

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 27

Simplified Electrical Schematic . . . . . . . . . . . . . 27

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

XM PFP System (262869, 24W626) . . . . . . . . . 32

Base System (262878, 24W648) Subassemblies 44

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 62

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 62

2 3A2989G

Models

Maximum Fluid

Working Pressure

Maximum Air Working

Pressure Approvals

A and B Materials:

6000 psi

(41 MPa, 414 bar)

Supply: 150 psi

262869

24W626

Flushing Fluid:

4500 psi

(31 MPa, 310 bar)

(1.0 MPa, 10.3 bar)

Max. Setpoint: 100 psi

(0.7 MPa, 7 bar)

Heating Fluid:

100 psi

(0.7 MPa, 7 bar)

Related Manuals

Manuals are available at www.graco.com. Component manuals in English:

Manual Description

3A2776 XM PFP Setup - Operation

3A2988 XM PFP Mix Manifold Instructions - Parts

3A2799 XHF Spray Gun

Certified to CAN/CSA C22.2 No. 88

9902471

Conforms to

UL 499

Manual Description

Accessories

332073 Hot Water Flush Kit Instructions

3A2987 Air Dryer Kit Instructions

Other

313342 Dosing Valve Instructions - Parts

Heaters

309524

3A2954

3A2824 Viscon LT Fluid Heater Instructions - Parts

Pumps, Motors, Supply Systems

308652

311238

311762

312375

312376

312792

312794 Merkur Pump Assembly Instructions - Parts

312796 NXT Air Motor Instructions - Parts

313526 Supply Systems Operation

313527 Supply Systems Repair - Parts

312374 Air Control Instructions - Parts

Viscon Instructions - Parts

Viscon HF High Flow, High Pressure Fluid Heater Instructions - Parts

Husky Pumps Instructions - Parts

NXT

Xtreme

Check-Mate® Displacement Pumps Instructions - Parts

Check-Mate Pump Packages Instructions Parts

Merkur® Pump Repair - Parts

HP High Pressure Fluid Heater

™

205 Air-Operated Diaphragm

Air Motor Instructions - Parts

Lowers Instructions - Parts

306861 Ball Valves Instructions - Parts

307005 High Pressure Swivel Instructions - Parts

308169

407061 Simulation XM PFP Display Module

3A1244

Air Filters, Lubricators, and Kits Instructions

- Parts

Graco Control Architecture Module Programming

3A2989G 3

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 or on warning labels, 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

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 or installing equipment.

• Connect only to grounded power source.

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

SKIN INJECTION HAZARD

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

• Do not 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.

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. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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.

4 3A2989G

Warnings

WARNING

WARNINGWARNINGWARNING

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.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

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

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS 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. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

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

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

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

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

TOXIC FLUID OR FUMES HAZARD

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

• Read 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.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective 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

SPLATTER HAZARD Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen,

splatter may occur.

• Use minimum air pressure when removing platen from drum.

3A2989G 5

Component Identification

Keep Components A and B Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination:

• Never interchange component A and component

B wetted parts.

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

Changing Materials

NOTICE

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

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

Component Identification

See XM PFP Operation manual for component identification.

Grounding

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

Ground the electrical connection properly according to local codes.

• Always clean any fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

Components A and B

IMPORTANT!

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

Be aware that in this manual:

Component A refers to resin or major volume. Component B refers to the hardener or minor volume.

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

6 3A2989G

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Engage trigger lock.

TI19265a2

2. If the system will be shut down for more than a few hours, perform Park Fluid Pump Rods procedure in XM PFP Operation manual to prevent fluid hardening on the pump shaft.

NOTICE

The material may expand when air pressure is removed. This can cause the tank to overfill and damage the parts attached to the tank lid. To prevent overfilling the tank, never relieve air pressure in the tank unless the tank is less than half full. Verify tank material level on the user interface, see Appendix A - User Interface Display section in XM PFP Operation manual.

5. If necessary to relieve tank air pressure: close both

feed system air control ball valves and back out the air pressure regulator. Open the brass valves on the tank lids for full tank de-pressurization. Pressure gauge should read 0 psi.

FEED PUMP

BYPASS

ti20127a

3. Press (Stop button).

4. Slide the feed pump air supply valve (DF) and director valve air supply valve (DA) to the OFF position.

. 1: Feed Pump Controls

ti20104a

. 2

6. Open mix manifold ball valves.

ti20128a

3A2989G 7

Troubleshooting

7. Open recirculation ball valves.

WLD

8. Disengage trigger lock.

TI19265a1

9. Hold a metal part of the gun firmly to a grounded metal pail. Trigger gun to relieve pressure in material hoses. Use a pail lid with a hole to dispense through. Seal around hole and gun with a rag to prevent splash back.

11. Close mix manifold material ball valves.

ti20129a

12. Perform Flush Mixed Material procedure in XM

PFP Operation manual to prevent mixed material curing in the system and to relieve pressure in the solvent lines.

13. Close metering pump air supply ball valve.

10. Engage trigger lock.

TI1953a

TI19265a2

14. If the system will be shutdown for more than a few hours, fill pump A and B packing nuts with throat

seal liquid (TSL

™

NOTE: Fluid pressure in the system is now relieved.

Troubleshooting

See XM PFP Operation manual 3A2776 for troubleshooting details.

8 3A2989G

Repair

NOTICE

Do not use air motor lift rings to lift the entire assembly. This will damage the system. The system must be lifted from the bottom.

Follow Pressure Relief Procedure on page 7 if service time may exceed pot life time, before servicing fluid components, and before transporting sprayer.

Replace Air Filter Element

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

3. Unscrew filter bowl from inlet air regulator (601d).

4. Remove and replace element.

601d

Filter Bowl and Element

r_312359_313289_15

5. Screw filter bowl on securely.

6. Replace front and rear shrouds (19, 20) using four nuts (21).

Main Air Inlet Manifold Filter

2. Unscrew filter bowl collar from main air inlet filter (14).

To reduce the risk of serious injury, do not service air filter until air line is depressurized. Removing a pressurized air filter bowl could cause serious injury.

Both Filters

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

Control Air Regulator Filter

2. Remove four nuts (21) and then remove front and rear shrouds (19, 20).

ti199526a1

3. Remove and replace filter element (701a). See Air Filter (24P899), page 49.

4. Reassemble filter bowl.

ti19926a1

3A2989G 9

Repair

User Interface/Control Box

Remove Shroud and Front Panel of Control Box

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

2. Remove four nuts (21) and then remove front and rear shrouds (19, 20).

2. Disconnect solenoid cable connector (542) from the solenoid (509a) being replaced.

3. Remove two screws (509b) from the solenoid being replaced then remove solenoid (509a). See F

. 4.

509b

r_xm1a00_312359_313289_9_3

509a

FIG. 4

4. Use screws (509b) to install new solenoid (509a).

ti19926a1

3. Disconnect power.

4. Remove four nuts (17); leave two nuts on left side of panel tight. Open front panel of control box (16). See F

. 3.

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. 3

5. Reconnect solenoid cable connectors (542). See

Control Box (255771) on page 47.

NOTE:

From left to right, solenoid functions are as follows:

• Dosing valve A (DVA) (normally open)

• Dosing valve B (DVB) (normally open)

• Pump A (PA) (normally closed)

• Pump B (PA) (normally closed)

DVA

DVB

r_xm1a00_312359_313289_9_3

Replace Single Solenoid Module

1. Remove Shroud and Front Panel of Control Box, see page 10.

10 3A2989G

Repair

Update USB Module Software

1. Remove four nuts (21) and then remove front and rear shrouds (19, 20).

ti19926a1

2. Use software token 16P644. See Graco Control Architecture

instructions.

NOTE: Upgrade all modules in the system to the software version on the token, even if you are replacing only one or two modules. Different software versions may not be compatible.

All data in the module may be reset to factory default settings. Record all settings and user preferences before the upgrade, for ease of restoring them following the upgrade.

™

Module Programming manual for

Replace USB Module

1. Remove Shroud and Front Panel of Control Box,

see page 10.

2. Disconnect CAN cables and USB cable from USB module (519).

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

r_312359_313289_23a

519

4. Follow steps in reverse order to install new USB module.

5. Load software. See Update USB Module Soft-

ware.

The latest software version for each system can be found at Tech Support at www.graco.com.

3A2989G 11

Repair

Update Fluid Control Module (FCM) Software

1. Remove four nuts (21) and then remove front and rear shrouds (19, 20).

ti19926a1

2. Use software token 16P644. See Graco Control Architecture

instructions.

NOTE: Upgrade all modules in the system to the software version on the token, even if you are replacing only one or two modules. Different software versions may not be compatible.

All data in the module may be reset to factory default settings. Record all settings and user preferences before the upgrade, for ease of restoring them following the upgrade.

™

Module Programming manual for

3. Loosen four mounting screws (535).

r_312359_313289_26

518

535

4. Slide FCM up and out of keyhole slots.

5. Follow steps in reverse order to install new FCM.

6. Load software. See Update Fluid Control Module (FCM) Software.

7. Most of the system configuration is stored in the FCM. Use the display to change the configuration to the values in the old FCM. See XM PFP operation manual for instructions.

Replace Alarm

1. Remove Shroud and Front Panel of Control Box, see page 10.

2. Disconnect alarm wires from alarm (517).

The latest software version for each system can be found at Tech Support at www.graco.com.

Replace Fluid Control Module (FCM)

NOTE:

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

1. Remove Shroud and Front Panel of Control Box,

see page 10.

2. Remove all cables from FCM (518). Take note of cable locations.

3. Unscrew alarm (517) and replace.

r_312359_313289_22

517

4. Screw in new alarm. Reconnect alarm wires.

5. Reinstall front panel of control box and reinstall shrouds.

12 3A2989G

Repair

Display

Upgrade Software

NOTICE

To avoid damaging circuit board, wear a grounding strap.

Use software token 16P644. See Graco Control Architecture

NOTE: Upgrade all modules in the system to the software version on the token, even if you are replacing only one or two modules. Different software versions may not be compatible.

All data in the module may be reset to factory default settings. Record all settings and user preferences before the upgrade, for ease of restoring them following the upgrade.

The latest software version for each system can be found at Tech Support at www.graco.com.

™

Module Programming manual for instructions.

6. Turn power off.

7. Remove token (T).

8. Use screws (512) to install access cover (511).

Replace Display Battery

NOTICE

To avoid damaging circuit board, wear a grounding strap.

1. Perform steps 1-2 in the Upgrade Software section

on page 13.

2. Use a flat head screwdriver to pry out old battery.

Remove Old Battery

Connector

Insert New Battery

r_xm1a00_312359_313289_9_8a

Tabs

1. Remove Shroud and Front Panel of Control Box,

see page 10.

2. Remove four screws (512) then remove access cover (511).

512

Battery

511

r_xm1a00_312359_313289_2a

3. Insert and press token (T) firmly into slot.

NOTE:

There is no preferred orientation of token.

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

NOTE:

Use only Panasonic CR2032 batteries for replacement.

4. Use screws (512) to install access cover (511).

4. Turn power on.

5. The red indicator light (L) will flash until new software is completely loaded.

3A2989G 13

Repair

Replace Display

NOTE: Order display kit 257484 for replacement.

NOTICE

To avoid damaging circuit board, wear a grounding strap.

1. Remove Control Box Shrouds, see page 17.

2. Disconnect CAN cable from display module.

3. Remove four screws (505) from rear display panel (506) while holding front display panel (507) in place.

NOTE:

To ease removal use clear tape to hold front display panel (507) in place.

507

6. Discard old display assembly.

7. Place new front display panel (507) and gasket (513) on front panel of control box (16).

NOTE:

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

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

9. Install new rear display panel (506) and secure with four screws (505). Ensure key switch cable protrudes from opening in top of display module.

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

11. Reconnect CAN cable to display module.

12. Reconnect power.

13. Load software. See Upgrade Software, page 13.

14. Replace shroud.

r_312359_313289_24a

15. Configure system settings as they were set on old display. See XM PFP Operation manual for instructions.

506

505

4. Remove rear display panel (505) and disconnect display cable and key switch cable (539) from circuit board.

5. Remove front display panel (507) and gasket (513).

Display Cable

539

507

513

r_xm1a00_312359_313289_25a

506

505

Replace Front Panel

See Replace Display, page 14, for instructions.

14 3A2989G

Repair

Junction Box

Update High Power Temperature Control Module (HPTCM, ref. 404) Software

NOTE: Upgrade all modules in the system to the software version on the token, even if you are replacing only one or two modules. Different software versions may not be compatible.

All data in the module may be reset to factory default settings. Record all settings and user preferences before the upgrade, for ease of restoring them following the upgrade.

The latest software version for each system can be found at Tech Support at www.graco.com.

1. Open junction box.

404

B HOSE A

Replace High Power Temperature Control Module (HPTCM, ref. 404)

ti21595a

1. Turn system main power switch OFF.

2. Open junction box.

3. Unplug all connections on the HPTCM.

ti20155a

2. Use software token 16P644. See Graco Control Architecture

™

Module Programming manual for

instructions.

4. Remove screws securing HPTCM then remove HPTCM.

5. Remove access door on new HPTCM. Set rotary switches to the same number as the old module. B module = 1. Hose module = 2. A module = 0.

ti12360a

6. Use screws to install HPTCM.

7. Reattach HPTCM connections.

8. Close junction box.

3A2989G 15

Repair

Update Fluid Control Module Cube (FCM3, ref. 415) Software

NOTE: Upgrade all modules in the system to the software version on the token, even if you are replacing only one or two modules. Different software versions may not be compatible.

All data in the module may be reset to factory default settings. Record all settings and user preferences before the upgrade, for ease of restoring them following the upgrade.

The latest software version for each system can be found at Tech Support at www.graco.com.

415

B HOSE A

3. Unplug all connections on the FCM3.

4. Remove two screws securing FCM3 then remove FCM3.

Center ground screw in the Fluid Control Module Cube must be used to avoid serious injury due to electric shock.

5. Use screws to install FCM3.

6. Reattach FCM3 connections.

7. Perform Update Fluid Control Module Cube (FCM3, ref. 415) Software on page 16.

8. Close junction box.

ti20155a

1. Open junction box.

2. Use software token 16P644. See Graco Control Architecture

™

Module Programming manual for

instructions.

Replace Fluid Control Module Cube (FCM3, ref. 415)

Ground screw

ti21594a

1. Turn system main power switch OFF.

2. Open junction box.

16 3A2989G

Repair

Air Controls

Remove Control Box Shrouds

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

2. Remove four nuts (21) and then remove front and rear shrouds (19, 20).

ti19926a1

Remove Air Control Assembly

1. Remove Control Box Shrouds.

2. Disconnect air motor air lines and system air line.

3. Remove four nuts (17) from front of air controls (18). See page 36.

4. Pull out assembly.

5. Follow steps in reverse order to reinstall air control assembly.

8. Follow steps in reverse order to reassemble.

Replace Solvent Air Regulator

1. Remove Control Box Shrouds.

2. Disconnect air motor air lines and system air line.

3. Remove four nuts (17) from front of air controls (18). See page 36.

4. Pull out assembly.

5. Remove regulator nut (631), and disconnect air lines (632, 633) running to regulator (625). See F 5 on page 18.

6. Remove regulator assembly and replace with new. See part number shown in the System Air Con- trols Module (255761) section beginning on page 44.

7. Follow steps in reverse order to reassemble.

Replace System Air Regulator

1. Remove Control Box Shrouds.

2. Disconnect air motor air lines and system air line.

3. Remove four nuts (17) from front of air controls (18). See page 36.

4. Pull out assembly.

5. Remove regulator nut (601h) and disconnect system air line.

Replace Solvent Pump Air Ball Valve

1. Remove Control Box Shrouds.

2. Disconnect air motor air lines and system air line.

3. Remove four nuts (17) from front of air controls (18). See page 36.

4. Pull out assembly.

5. Remove two nuts (630) from front of air control bracket (619). See F

6. Disconnect air line (632) running to ball valve assembly (626).

7. Replace with new ball valve assembly. See part number shown in the System Air Controls Module (255761) section beginning on page 44.

3A2989G 17

. 5 on page 18.

6. Remove screws from quick clamps and open clamps (601f) at hinge.

7. Remove regulator assembly (601c) and replace with new. See part number shown in the System Air Controls Module (255761) section beginning on page 44.

8. Follow steps in reverse order to reassemble.

Replace Solenoid Inlet Air Regulator

1. Remove Control Box Shrouds.

2. Disconnect air motor air lines and system air line.

3. Remove four nuts (17) from front of air controls (18). See page 36.

4. Pull out assembly.

Repair

5. Disconnect air line.

6. Remove gauge (606) from block (601e).

7. Remove screws from quick clamps (601f) holding air regulator assembly (601c) in place.

8. Open clamps (601f) at hinge and pull apart from block (601e).

617

607

613

603

626

629

632

619

638

636

637

632

635

9. Remove regulator assembly (601d) and replace

with new. See part number shown in the System Air Controls Module (255761) section beginning on page 44.

10. Follow steps in reverse order to reassemble.

11. Set new air pressure regulator to at least 80-85 psi

(0.55-0.58 MPa, 5.5-5.8 bar).

616

644

608

610

611

Ref. 27

645

642

612

609

615

617

613

618

630

. 5

640

631

627

618

628

633

625

629

634

635

633

606

621

620

622

643

642

641

604

646

647

18 3A2989G

Dosing Valve Assembly

Repair

1. Follow Pressure Relief Procedure, page 7.

2. Disconnect all fluid lines from dosing valves (28 or

29). See F

3. Remove two bolts (31) securing dosing valve to bracket.

4. Unscrew dosing valve nipple fitting (36 or 37) from dosing valve outlet.

5. Disconnect pressure sensor (831) from dosing valve. See page 50.

. 6.

6. Remove dosing valves.

7. See Ratio Control Valve Assemblies on page 50

for disassembly illustration.

8. Follow steps in reverse order to reassemble dosing

valve assembly. See Ratio Control Valve Assem- blies on page 50 for assembly illustration and specifications.

FIG. 6

3A2989G 19

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