Graco XP70 User Manual

Instructions-Parts

XP70 Plural-Component

3A0420H

Sprayer

Complete mechanical fixed ratio plural-component sprayer used for proportioning, mixing, and spraying two component quick setting materials. 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.

Patents Pending

XP70 Sprayer shown with hoppers and optional solvent flush pump and heaters.

r_571100_3A0420A_1a-2

c IIA T2

II 2 G

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 XP70 Sprayers . . . . . . . . . . . . . . 11

Bare Proportioning Pump Packages . . . . . . . . . 11

Component Identification . . . . . . . . . . . . . . . . . . . 12

Fluid Control Assembly . . . . . . . . . . . . . . . . . . . 13

Main Air Controls . . . . . . . . . . . . . . . . . . . . . . . 13

45:1 Solvent Flush Pump Kit 262393 (optional) 14

Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 15

Flush Before Using Equipment . . . . . . . . . . . . . 15

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Wire Sprayers with Explosion-Proof Heaters . . 17

Air Motor Position . . . . . . . . . . . . . . . . . . . . . . . 18

Connect Air Supply . . . . . . . . . . . . . . . . . . . . . . 19

Connect Static Mixers, Gun, and Hoses . . . . . . 19

Connect Fluid Hose Bundles (Remote Only) . . 19

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 20

Prime Empty Sprayer . . . . . . . . . . . . . . . . . . . . . . 21

Prime A and B Fluids . . . . . . . . . . . . . . . . . . . . 21

Prime Solvent Flush Pump . . . . . . . . . . . . . . . . 22

Recirculate or Re-Prime After a Pump Runs Dry 23

Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

B Side Mix Manifold Restriction . . . . . . . . . . . . . . 25

Flush Mixed Material . . . . . . . . . . . . . . . . . . . . . . . 26

Flush Mix Manifold, Hose, and Spray Gun . . . . 26

Empty and Flush Entire System

(new sprayer or end of job) . . . . . . . . . . . . . . 27

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

System Verification . . . . . . . . . . . . . . . . . . . . . . . . 29

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . 30

Recommended Spare Parts . . . . . . . . . . . . . . . 30

Change the Mix Ratio . . . . . . . . . . . . . . . . . . . . 30

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . 32

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 33

Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Mix Manifold Assembly . . . . . . . . . . . . . . . . . . . 36

Fluid Circulation Manifold . . . . . . . . . . . . . . . . . 36

Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Optional Fluid Heaters . . . . . . . . . . . . . . . . . . . . 39

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Cart-Mounted XP70 Sprayer . . . . . . . . . . . . . . . 40

Bare Proportioning Pump Package . . . . . . . . . . 44

Air Controls, 258983 . . . . . . . . . . . . . . . . . . . . . 46

Fluid Manifold, 258990 . . . . . . . . . . . . . . . . . . . 47

Recommended Spare Parts . . . . . . . . . . . . . . . . . 48

Pump Performance Charts . . . . . . . . . . . . . . . . . . 49

Calculate Fluid Outlet Pressure . . . . . . . . . . . . . 49

Calculate Pump Air Flow/Consumption . . . . . . . 49

Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . 52

Acceptable For Use in Explosive Atmospheres . 52

Not Approved For Explosive Atmospheres . . . . 52

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Bare Proportioner Mounting Hole Dimensions . 55

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 56

2 3A0420H

Related Manuals

Manuals are available at www.graco.com

Component Manuals in English:

Manual Description

311762

311238

3A0590

312747

309524

312145

312769

312794

Xtreme Instructions-Parts

NXT Mix Manifold

Instructions-Parts 20 Gallon Double Wall Hopper Kit

Instructions-Parts

Viscon

XTR Instructions-Parts

Feed Pump and Agitator Kits Instructions-Parts

Merkur Instructions-Parts

310863 Feed and Solvent Flush Kits

406860

7-Gallon Hopper Installation Kit Instructions-Parts

406739 Desiccant Kit Instructions-Parts

309852

406861

Polyurethane Circulation and Return Tube Kits, Instructions-Parts

Viscon HP Heater Adapter Kit, Instructions-Parts

3A0421 Ratio Check Kit, Instructions-Parts

309525 Heated Hose Kit, Instructions-Parts

309964

339361

311486

Gun Splitter Valve with Independent Flush, Instructions-Parts

High Pressure Hose and Accessories Brochure

DataTrak tions-Parts

Displacement Pumps

Air Motor Instructions-Parts

HP Heater Instructions-Parts

™

5 and XTR™ 7 Spray Guns

Pump Assembly

™

Conversion Kit, Instruc-

Related Manuals

3A0420H 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, 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 3A0420H

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 ser- vicing 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 component. See Technical Da t a 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.

3A0420H 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 3A0420H

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

Foam Resins with 245 fa Blowing Agents

Some foam blowing agents will froth at temperatures 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.

3A0420H 7

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 sprayer 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-

XP70

™

and PR

™

and VRM

Hydra-Cat

™

Mix

, XM™, and

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

Red Blue

ISO, Hardener,

Catalyst

Low Volume

Side

Blue Green

Resin, Base

High Volume

Side

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 3A0420H

Overview

Usage

The XP70 plural-component sprayer is a mechanical fixed ratio sprayer 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.

The two pumps are carbide seat severe duty positive displacement pumps that displace fluid on both strokes simultaneously on ratio to one another.

XP70 sprayers are not approved for use in hazardous locations unless the base model, all accessories, all kits, and all wiring meet local, state, and national codes. See Important Two-Component Material Information, page 7, to determine the appropriate location for your particular sprayer model.

Overview

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.

• Maximum air pressure set point blow off valves are provided to limit maximum fluid pressure. Do not remove these valves.

• Automatic pressure relief valves are used to dump excess pressure back to the supply. Never plug these return hoses.

• Common handles link the fluid control valves. Never install individual shut off valves on the “A” and “B” lines.

• On models other than 1:1 mix ratio, a rupture disc is provided on the small side fluid pump 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.

3A0420H 9

Initial System Setup

Complete the following steps in the order they are listed, as they apply to your specific system, for initial system setup.

1. Check the shipment for accuracy. Ensure you have received everything you ordered. See Component Identification, page 12.

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. See manual 309852 if you are feeding urethane material.

NOTE: Supply return lines must be used.

7. Connect the feed pumps, fluid strainers, and air hoses as necessary. If your sprayer does not use hoppers, then see manual 312769.

8. Connect the air supply line. See Connect Air Sup- ply, page 19.

9. Connect the fluid hose assembly, including the static mixers, whip hose and gun. See Pressure Relief Procedure, page 20.

10. Flush test oil from system as needed. See Empty

and Flush Entire System (new sprayer or end of job), page 27.

10 3A0420H

Models

XP70 sprayers 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 XP70 Sprayers

All XP70 sprayers include static mixers, 3/8 x 25 ft hose, clean up mixer, 1/4 x 10 ft (x m) whip hose, and XTR 7 spray gun with a 519 tip. See Accessories and Kits on page 52 for a list of all optional accessories.

Volu me

Mix

Sprayer

571101 1:1 571100 7250 (50, 500) 95 (0.6, 6.5) 571102 1:1 571100 571151 1.5:1 571150 7250 (50, 500) 80 (0.5, 5.5) 571152 1.5:1 571150 571201 2:1 571200 7250 (50, 500) 95 (0.6, 6.5) 571202 2:1 571200 571251 2.5:1 571250 6500 (45, 448) 100 (0.7, 7) 571252 2.5:1 571250 571301 3:1 571300 6800 (47, 469) 100 (0.7, 7) 571302 3:1 571300 571401 4:1 571400 7250 (50, 500) 100 (0.7, 7) 571402 4:1 571400

Ratio

Pump

Package

7 Gallon Hoppers

✔

Maximum Fluid

Working Pressure

psi (MPa, bar)

7250 (50, 500) 95 (0.6, 6.5)

7250 (50, 500) 80 (0.5, 5.5)

7250 (50, 500) 95 (0.6, 6.5)

6500 (45, 448) 100 (0.7, 7)

6800 (47, 469) 100 (0.7, 7)

7250 (50, 500) 100 (0.7, 7)

Maximum Air

Working Pressure

psi (MPa, bar)

Fluid/Air

Pressure Ratio

76:1

91:1

76:1

65:1

68:1

73:1

Bare Proportioning Pump Packages

All pump packages use a NXT Air Motor N65DN0.

Combined

Volu me

Pump

Package

571100 L085C0 L085C0 1:1 173 76 1.8 (6.8) 7250 (50, 500) 95 (0.6, 6.5) 571150 L085C0 L058C0 1.5:1 144 91 1.5 (5.6) 7250 (50, 500) 80 (0.5, 5.5) 571200 L115C0 L058C0 2:1 174 76 1.8 (6.8) 7250 (50, 500) 95 (0.6, 6.5) 571250 L14AC0 L058C0 2.5:1 203 65 2.1 (7.9) 6500 (45, 448) 100 (0.7, 7) 571300 L14AC0 L048C0 3:1 193 68 2.0 (7.5) 6500 (45, 448) 100 (0.7, 7) 571400 L14AC0 L036C0 4:1 181 73 1.9 (7.1) 7250 (50, 500) 100 (0.7, 7)

A Side

Pump

B Side

Pump

Mix

Ratio

Fluid

Output

cc/cycle

NXT6500

Fluid/Air

Ratio:1

Fluid Flow

at 40 cpm

gpm (lpm)

Maximum Fluid

Working Pressure

psi (MPa, bar)

Maximum Air

Working Pressure

psi (MPa, bar)

The pump size is marked on the pump cylinders.

3A0420H 11

Component Identification

Mounting Components for

Pump Package

FIG. 1: XP70 Sprayer with optional accessories

Key:

A Air Motor Supply Hose B Main Air Controls; see page 13 C Air Inlet - 3/4 Npsm(F) D High Pressure Fluid Pump E Air Motor F Fluid Heater (optional) G Solvent Flush Pump (optional); see page 14 H Solvent Flush Pump Air Controls; see page 14 J 7 Gallon Hoppers (optional) KCart LBrake M Handle (lift to release)

r_571101_3a0420a_1a-2

N Fluid Control Assembly; see page 13 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 Y Over Pressure Rupture Disc;

only 38cc, 48cc, and 58cc pumps

12 3A0420H

Fluid Control Assembly

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 AK A and B Mix Manifold Check Valves AL Solvent Inlet Check Valve AM Automatic Over-Pressure Relief Valves;

with grease fittings

AN A and B Combined Outlet; 3/8 npt(m)

FIG. 2

Main Air Controls

r_571101_3a0420a_3a-2

Key:

CA Main Air Motor Shutoff Valve (Relieving) CB Main Motor Pressure Regulator CC Air Filter with Auto Drain CD Main Pump Air Regulator Gauge CE Filtered Air Distribution Manifold

FIG. 3

3A0420H 13

Component Identification

45:1 Solvent Flush Pump Kit 262393 (optional)

Key:

BA Solvent flush pump (Merkur Pump)

BB Fluid Inlet BD Muffler BE Prime/Flush/Sample valve BF Fluid Outlet Hose BG Circulation hose

r_571100_3a0420a_4a-2

FIG. 4: Solvent Flush Pump Kit

Air Controls

Included with optional solvent flush pump kit 262393.

BB (suction hose not shown)

Key:

DA Solvent Pump Air Shutoff Valve (Relieving) DB Solvent Pump Air Regulator DC Solvent Pump Air Regulator Gauge DD Air Outlet DE Air Inlet

r_571101_3a0420a_5a-2

FIG. 5: Solvent Flush Pump Kit Air Controls

14 3A0420H

Component Identification

Air Line

Bleed-type master air valve (CA): required in your sys-

tem to relieve air trapped between it and the air motor when the valve is closed.

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

• Be sure the valve is easily accessible from the pump and located downstream from the air regulator.

• Pump air regulator (CB): to control pump speed and outlet pressure.

• Air line filter (C): 40 micron filter that 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): to heat the resin and hardener before mixing. Improves the chemical reaction and lowers viscosity to improve the spray pattern.

• Optional Solvent Flush Kit (G): to flush 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 sprayer or end of job), page 27.

• Fluid Manifold (AA): mounts fluid gauges and over pressure relief valves. Controls circulation and pump priming.

• Mix Manifold (AB): brings A and B fluid together. Provides control and check valves for A, B, and flush fluids.

• Circulation Handle (AC): open to relieve fluid pres- sure, prime pumps, and circulate material in hoppers. Close to spray mixed material.

• Dual Shutoff Handle (AE): Controls A and B on/off flow into mix manifold. Press down to provide A and B fluid to the mix manifold and into the static mixer for spraying. Press up to turn off A and B before flushing the mixed material.

• Solvent Flush Valve (AD): to flush solvent through mix manifold, hose, and spray gun.

• Static mixer/gun hose kit: to mix the two fluids and deliver mix to the spray gun. Includes static mixer and hoses to the spray gun.

3A0420H 15

Setup

Location

XP70 sprayers 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 54.

4. Ensure that the cart brake (L) is in the locked position.

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.

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. If total resistance to ground exceeds 29 megohms, replace hose immediately.

Air compressor: follow manufacturer’s recommendations.

Grounding

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.

Spray gun: ground through connection to a properly

grounded fluid hose and pump.

Fluid supply container: follow local code.

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.

16 3A0420H

Wire Sprayers with Explosion-Proof Heaters

(Hazardous location sprayers only)

If your sprayer 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.

3A0420H 17

Setup

Air Motor Position

The air motor position must be set for the mix ratio of the machine, which is defined by which two pumps are mounted.

1. Verify that the correct pumps are mounted for your mix ratio by volume. See chart in Bare Proportion- ing Pump Packages on page 11.

2. Verify that the motor position is adjusted correctly for that mix ratio.

indicator line

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FIG. 6: Ratio indicators

2. Place wrench on adapter rod (104).

3. Use tool (70) to loosen the serrated yoke nut (V) above the yoke (T).

104

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4. Loosen the three nuts (P2) below the motor tie rods.

piston rod

Position Air Motor

There are specific positions for each fixed ratio setting. To adjust the position of the air motor:

1. Loosen the eight fasteners and remove the two pump guards.

fastener

pump guard

fastener

pump guard

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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.

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). Use tool (70) to tighten the yoke nut.

7. Install the pump guards.

18 3A0420H

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

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2. Remove plugs as necessary for solvent pump and feed supply pump air hoses. See pump manuals for setup instructions.

Connect Fluid Hose Bundles (Remote 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.

Connect Static Mixers, Gun, and Hoses

NOTICE

To prevent creating a flare on the mixer tube, do not use an 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. 7.

27, 28

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FIG. 7

3A0420H 19

Pressure Relief Procedure

Follow Flush Mixed Material, page 26 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).

Relieve A and B Fluid Pressure

1. Engage the trigger lock.

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2. Close the main air shutoff valve (CA).

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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.

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10. Always flush the mix hose after relieving A and B fluid pressure through the mix manifold. See Flush Mixed Material, page 26.

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

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loosen static mixer tube from mix manifold 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.

20 3A0420H

Prime Empty Sprayer

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 sprayer or end of job), page 27.

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.

4. Close the dual shutoff handle (AE) and open the circulation handle (AC).

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5. Open the main air shutoff valve (CA).

6. Slowly open the air regulator (CB).

7. Dispense fluid in to 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 or Re-Prime After a Pump Runs Dry, page 23.

3A0420H 21

Prime Empty Sprayer

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.

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6. Ensure the trigger lock is engaged. Remove the spray tip.

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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.

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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 back to the pail. Close the solvent pump fluid valve (BE) and air valve (DA).

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5. Open the solvent flush valve (AD) on the mix manifold.

AE (closed)

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.

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10. Close the solvent flush valve (AD).

NOTE: Solvent pump air and pressure may be left on while spraying. Never spray mixed material without the solvent pump and hose primed with solvent.

22 3A0420H

Prime Empty Sprayer

Recirculate or Re-Prime After a Pump Runs Dry

Without Heat

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 Sprayer, page 21.

2. Close the dual shutoff handle (AE).

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3. Ensure the recirculation hoses (U) are in the correct hoppers (J).

6. If the pumps are running too quickly, adjust the main air regulator (CB) to regulate the cycle rate.

7. Run the pumps for a few minutes or until the material has reached the desired temperature. See Heat Fluid.

8. Close the main air shutoff valve (CA).

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9. See Spray, page 24.

With Heat

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.

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

4. Open the circulation valve handle (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.

3A0420H 23

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.

NOTE: Agitate, recirculate, and heat the material only as necessary to avoid mixing air into the fluid.

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 20, 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

23. Circulate as necessary.

2. Close the circulation handle (AC) and the solvent flush valve (AD). Open the dual shutoff handle (AE).

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 flush solvent out of the mix hose until a well mixed coating flows from the gun.

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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 29.

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 26 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.

24 3A0420H

B Side Mix Manifold Restriction

If the mix manifold (AB) is mounted on the machine, you do not need to adjust the restrictor (AJ). Leave open two turns minimum.

The B side restrictor (AJ) in the mix manifold is only used when the mix manifold is positioned remote from the machine with a short mix hose to the spray gun, or it has been adjusted as part of the ratio check procedure.

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.

Adjust the restrictor stem (AJ) 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.

3A0420H 25

Flush Mixed Material

Flush the mix manifold when any of the following situations occur.

• breaks in spraying

• overnight shutdown

• end of potlife

To flush the entire system, see Empty and Flush Entire

System (new sprayer or end of job), page 27.

Flush Mix Manifold, Hose, and

4. Open the solvent flush valve (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. Flush out mixed material 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 sprayer or end of job), page 27.

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.

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2. Close the dual shutoff handle (AE).

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6. Close the solvent pump air valve (DA). Trigger the gun to relieve pressure. Close the solvent flush valve (AD) after relieving the pressure.

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7. Follow Pressure Relief Procedure, page 20.

3. Open the solvent pump air valve (DA). Slowly turn the solvent pump air regulator (DB) clockwise to

8. Engage the trigger lock. Disassemble and clean the spray tip with solvent by hand. Reinstall on the gun.

increase air pressure.

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26 3A0420H

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Empty and Flush Entire System (new sprayer 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.

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• 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 26.

• 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 sprayer 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.

3. Move the recirculation lines (U) to separate fluid containers to pump remaining fluid out of the system.

4. Open the circulation handle (AC). Increase the main pump air regulator (CB) pressure to 20 psi (138 kPa,

1.38 bar).

5. Open the main air shutoff valve (CA).

Procedure

1. Follow Prime Empty Sprayer, page 21 and Flush Mix Manifold, Hose, and Spray Gun, page 26, as

required.

3A0420H 27

NOTE: If the sprayer 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).

Shutdown

6. Run the pumps until the A and B hoppers (J) are empty. Salvage the material in separate, clean containers.

7. Close the main air shutoff valve (CA).

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8. Wipe the hoppers (J) clean, then add solvent to each. Move the circulation lines (U) to waste containers and push out the dirty fluids.

9. Move the recirculation lines (U) back to the hoppers. Continue recirculating until the system is thoroughly flushed.

12. Close the dual shutoff handle (AE).

13. 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.

10. Close the circulation handle (AC) and open the dual shutoff handle (AE).

11. Dispense fresh solvent through the mix manifold valves and out the gun. Turn off the air motors and relieve all pressures.

Shutdown

1. Follow Pressure Relief Procedure, page 20.

2. Flush mix manifold, hoses, and gun. See Flush Mix Manifold, Hose, and Spray Gun, page 26.

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).

28 3A0420H

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 32.

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 a metal substrate. 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 and cause 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.

3A0420H 29

Maintenance

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 34.

• 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 20, prior to tightening seals. There must be zero pressure on the

pumps when adjusting.

Pump Size Torque Specification

36cc-85cc 50-75 ft-lb (68-100 N•m)

115cc and 145 cc 100-125 ft-lb (135-170 N•m)

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 sprayer.

Recommended Spare Parts

Keep these spare parts on hand to reduce downtime. See Recommended Spare Parts, page 48.

Change the Mix Ratio

In order to change the mix ratio, one or both pumps need to be replaced and the air motor needs to be re-positioned.

NOTE: Only Xtreme XP lower pumps come with a rod coupling.

1. Check the Varying Parts table on page 45 for the correct pump sizes.

2. Remove and replace pump. See page 33.

Cleaning Procedure

1. Ensure all equipment is grounded. See Grounding, page 16.

2. Ensure the area where the sprayer 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 26.

5. Relive pressure. See Pressure Relief Procedure, page 20.

6. Shutdown the prayer and turn off all power. See Shutdown, page 28.

3. Adjust the position of the air motor. See page 18.

4. Change air pressure relief valve as required, depending on ratio. See air relief valve (64) in tables on page 43.

30 3A0420H

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 valve cartridge (302) with kit

Overpressure rupture disk blown. Determine cause of overpressuriza-

Feed pressure too high. Every pound of feed pressure adds 2 psi boost during upstroke.

Open or clean.

Repair pump; see 311762.

Clean, repair pump; see 311762.

manifold restrictor.

Clean, repair pump; see 311762.

Tighten; replace; see 311762.

262520.

tion and correct. Replace rupture disk assembly (140) and over-pressure cartridge (302).

Reduce feed pressure. See Techni- cal Data, page 53.

3A0420H 31

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 others 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

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Hardener Pump

TROUBLE AREA: Hardener Pump Leakage

1. Throat packing

2. Intake ball check

Resin Pump

FallingRising

Hardener Pump

FallingFalling Rising Rising

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32 3A0420H

Repair

To avoid serious injury due to the pump assembly falling, secure a hoist to the lift ring.

Follow Shutdown, page 28, if service time may exceed pot life time, before servicing fluid components, and before transporting sprayer to a service area.

Repair

4. Remove the spring clamp (130) and coupling (119 or 120).

106

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. Cycle the yoke and pump rods near the bottom of their stroke. Follow Shutdown, page 28.

2. Disconnect all hoses from the pump assembly.

3. If hoppers are installed, disconnect the hoppers from the pump fluid inlet. See Hoppers, page 38.

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).

Remove Displacement Pump

1. Follow Shutdown, page 28.

2. If hoppers are installed, remove the hopper and hopper bracket from the cart. See Hoppers, page

38.

135

117

108

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.

7. Follow the steps in reverse order to reinstall the displacement pump.

NOTE: Torque nuts (108) to 50-60ft-lb (68-81 N•m).

105

130

119

118

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3. If feed pumps are installed, close the inlet ball valve. Remove inlet union (61).

3A0420H 33

Repair

Remove Air Motor

1. Cycle the yoke and pump rods near the bottom of their stroke. Follow Shutdown, page 28.

2. Disconnect the air line from the air motor (103).

3. Remove the air motor rod cover (121) and pump guards (122).

103

121

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.

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 Air Motor Position on page 18 for instructions. Torque nuts (108) to 50-60ft-lb (68-81 N•m).

Air Controls

See FIG. 8 on page 35.

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 46.

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

46.

4. Follow the steps in reverse order to reassemble.

7. Use a hoist to remove the air motor by the lift ring.

34 3A0420H

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. 8: Air Control Assembly 258983

3A0420H 35

Repair

Mix Manifold Assembly

1. Follow Pressure Relief Procedure, page 20.

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

r_571101_3a0420a_38a

r_571101_3a0420a_39a

FIG. 9: Fluid Circulation Manifold

Replace Drain Valve Cartridges

1. Flush before repairing equipment, if possible. See

Empty and Flush Entire System (new sprayer or end of job), page 27.

2. Follow Pressure Relief Procedure, page 20.

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

See FIG. 9.

1. Flush before repairing equipment, if possible. See

Empty and Flush Entire System (new sprayer or end of job), page 27.

2. Follow Pressure Relief Procedure, page 20.

3. Disconnect all fluid hoses from the fluid circulation manifold (35).

4. Remove the mix manifold 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 cartridge valves from the manifold.

5. Apply blue threadlock to new cartridge valves (302) and install in the manifold. Torque to (28-32 ft-lbs. (38-43 N•m).

6. Place a spring (320) over each valve stem. Place a clip (318) in each valve stem groove to retain springs.

7. Slide on a handle (311) and turn the stem approximately 90° until you feel it fully lock against the valve seat. Repeat for opposite side.

312

311

313

302

304

320

318

r_258988_3a0420a_2b

36 3A0420H

8. Place a handle (311) on a valve stem (302) at the vertical, or near vertical, spray 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.-lbs. (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.

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.

Repair

• Both valve stems should rotate out to their most extended positions when the handle is pulled down to the circulate position.

3A0420H 37

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

Solvent Pump

1. Follow Pressure Relief Procedure, page 20.

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.

plug

3. Follow Pressure Relief Procedure, page 20.

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.

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.

38 3A0420H

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 20.

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

3A0420H 39

Parts

Cart-Mounted XP70 Sprayer

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

r_571101_3a0420a_30a

40 3A0420H

r_571101_3a0420a_30a

Cart-Mounted XP70 Sprayer Continued

Parts

r_571101_3a0420a_44a-1

27, 28

r_571101_3a0420a_45a

49 “A”

49 “B”

65 (inside hopper)

TI17434a

3A0420H 41

Parts

Common Parts

Ref. Part Description Qty.

1 258913 CART 2 262476 AXLE, vertical 3 111841 WASHER, flat; 5/8 4 PACKAGE, pump; see page 44 5 100133 WASHER, lock; 3/8 6 100101 SCREW, cap, hex hd; 3/8-16 x 1 7 113362 WHEEL, semi-pneumatic 8 154628 WASHER; 3/4 9 113436 RING, retaining 10 124410 BEARING, sleeve,

1.00 x 1.25 x 1.5 11 124664 WASHER, thrust 12 262477 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;

see page 46 21 111218 CAP, tube, square 22 158491 FITTING, nipple; 1/2 in., 7400 psi 23 15M987 FITTING, elbow, 60°; 1/2 in.,

7250 psi 24 H75003 HOSE, coupled, 7250 psi, 1/2 ID,

3 ft 25 H73825 HOSE, coupled, 7250 psi, 3/8 ID,

25 ft 26 15B729 COUPLING; 3/8 m x f, 7250 psi 27 262478 HOUSING, mixer 28 248927 KIT, mixer element, 25 pack 29 150287 COUPLING; 3/8(f) x 1/4(m),

7250 psi 30 H72510 HOSE, coupled, 7250 psi, 1/4 ID,

10 ft 31 XTR704 GUN, XTR7, round handle, 4 finger

RAC, 519 32 162024 COUPLING; 3/8 m x f 33✖ 552069 LABEL, metalized 35 258990 MANIFOLD, recirculation;

see page 47 36 258989 MANIFOLD, mix; see mix manifold

manual 3A0590 37 106212 SCREW, cap, hex hd; 3/8-16 x 2.5 38 108063 GRIP, handle 41 158683 FITTING, elbow, 90°; 1/2 st 47 206995 FLUID, TSL, 1 qt. 48 101566 NUT, lock; 3/8-16 49▲ 15U654 LABEL, A and B (set of 4)

Ref. Part Description Qty.

50 100333 SCREW, hex hd, sst; 1/4 x 1/2 zn 52 124293 BOLT, u-bolt, 3/8-16, 1 dia.

53 124259 BRAKE, plunger clamp

54 124291 PIN, spring

58 116704 ADAPTER, 9/16-18 JIC x 1/4 npt

59 262481 TUBE, recirculation

65 16791 STRAINER

68✖ 114958 STRAP, tie

69▲ 15U654 LABEL, warning

70 16F615 TOOL, yoke nut, wet cups, and

2 1

89 16G819 TOOL, wrench, filter cap 90 16J688 PLUG, hole gauge

2 1

▲ Replacement Danger and Warning labels, tags, and

4 2 1 2 1

4 4 2

1 3 1 2

2 1 1

2 2 2 1 2 1

cards are available at no cost.

✖ Not shown.

pump inlets

4 1 1 2 2 2 1 2 1 1

1 1

42 3A0420H

Parts Varying by Model with Hoppers

XP70 Plural-Component Sprayer Models

Ref. Part Description

4 571100 PUMP, fixed ratio, 1:1

571150 PUMP, fixed ratio, 1.5:1 571200 PUMP, fixed ratio, 2:1 571250 PUMP, fixed ratio, 2.5:1 571300 PUMP, fixed ratio, 3:1

571400 PUMP, fixed ratio, 4:1 18 100131 NUT, full hex; 3/8-16 7 7 7 7 7 7 55 24E872 BRACKET, hopper,

painted 56 262479 HOPPER, blue 57 262480 HOPPER, green 60 H52506 HOSE, coupled, 5600 psi,

1.4 ID, 6 ft

61 16D376 FITTING, swivel, 1-1/4,

mod, w/plug 62 111192 BOLT, flange hd; 3/8-16 4 4 4 4 4 4 64 113498 VALVE, relief, air, 110 psi

116643 VALVE, relief, air, 90 psi

65 262482 STRAINER, hopper, 7 gal-

lon; 0.203 in. openings 66 124450 CLAMP, spring, con-

stant-tension 67▲ 15T468 LABEL, warning

571102 571152 571202 571252 571302 571402

2 2 2 2 2 2

1 1 1 1 1 1 1 1 1 1 1 1

2 2 2 2 2 2

1 1 1 1 1

2 2 2 2 2 2

1 1 1 1 1 1

2 2 2 2 2 2

Parts

Parts Varying by Model with No Hoppers

Ref. Part Description

4 571100 PUMP, fixed ratio, 1:1

571150 PUMP, fixed ratio, 1.5:1 571200 PUMP, fixed ratio, 2:1 571250 PUMP, fixed ratio, 2.5:1 571300 PUMP, fixed ratio, 3:1

571400 PUMP, fixed ratio, 4:1 18 100131 NUT, full hex 60 H52510 HOSE; 1/4 x 10 ft 64 113498 VALVE, relief, air, 110 psi

116643 VALVE, relief, air, 90 psi

XP70 Plural-Component Sprayer Models

571101 571151 571201 571251 571301 571401

1 3 3 3 3 3 3 222222 1 1 1 1 1

3A0420H 43

Parts

Bare Proportioning Pump Package

103

2 3

123

128

121

101

104

109

102

110

137

136

129

133

134

3 6

122

101

138

106

105

135

139

122

107

108

111

113

131 116

114

112

119

116

130

120

130

r_258914_3A0420A_2a

Torque together to 50-60 ft-lbs (68-81 N•m).

Torque to 145-155 ft-lbs (196-210 N•m).

Apply blue thread sealant.

Insert lanyard from locking pin onto pumps (17, 18) as shown.

Do not apply lubricant.

Torque to 70-80 ft-lbs (95-108 N•m).

Apply lithium grease to mating tapered surfaces.

140

117

118

108

r_258914_3A0420A_3a

44 3A0420H

Common Parts

Parts

Ref. Part Description Qty.

101 262465 PLATE, motor 1 102 262466 ROD, tie, 4.00 long,1.00 dia 3 103 N65DN0 MOTOR, 6500, de-icing, standard 1 104 262467 ROD, adapter 1 105 262468 ROD, tie, 14.25 long, w/shoulder 4 106 262469 ROD, tie, 14.25 long, 1.25 dia 2 107 154636 WASHER, flat; 5/8 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, bearing 2 114 15C244 BEARING, sleeve 4 116 123976 RING, snap, external 2 121 262473 COVER, motor rod 1 122 262474 COVER, pump 2 123 LABEL, identification 1

Varying Parts

Ratio 1:1 1.5:1 2:1 2.5:1 3:1 4:1

Ref. Part Description Qty.

128 NXT102 KNOB, de-ice, 5 pack 1 129 16D029 LABEL, XP70 1 130 124078 CLAMP, spring, constant-tension 2 131▲ 15H108 LABEL, pinch point 1 133 114225 TRIM, edge protection 2 134 262475 BRACKET, ratio indicator 1 135 16E882 STRAP, lowers 2 136 SCREW, cap, button hd; 10-32 8 137 WASHER, retaining, nylon 8 138 124665 NUT, captive; 10-32 4 139▲ 15T468 LABEL, warning 2 141 206995 FLUID, tsl, 1 qt. 1 142 244524 WIRE, ground assembly with

clamp

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

Ref. Description

117 A-Side pump

(see manual 311762)

118 B-Side pump

(see manual 311762) 119† A-Side coupler 120† B-Side coupler 140❖ B-Side rupture disc

❖ Included with B-Side pump assembly.

† Included with new pump assemblies (117, 118).

L085C0 L085C0 L115C0 L14AC0 L14AC0 L14AC0 1

L085C0 L058C0 L058C0 L058C0 L048C0 L036C0 1

247167 247167 247167 244819 244819 244819 1 247167 247167 247167 247167 247167 247167 1

258962 258962 258962 258962 258962 1

Qty.Part 571100 571150 571200 571250 571300 571400

3A0420H 45

Parts

Air Controls, 258983

201

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.

Connect hose (214) to fitting (206) and air distribution manifold (213).

Ref. No. Part No. Description Qty.

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 m x f 2 207 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 Qty.

211 157785 FITTING, union; 3/4 m x f 2 213 15E145 MANIFOLD, air distribution 1 214 16E004 HOSE, coupled, air; 26 in. (660.4

mm) 215 157350 NIPPLE; 3/8 x 1/4 npt 3 216 115781 CAP PLUG; 1/4 npt 3

✖ Not shown.

46 3A0420H

Fluid Manifold, 258990

Parts

313

312

309

308

311

318

320

304

308

309

303

310

2 3

302

313

305

320

317

318

301

311

317

305

304

307

302

2 3 4

336

316

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

Torque to 28-32 ft-lbs (38-43 N•m).

Apply blue anaerobic adhesive to threads.

Ref. No. Part No. Description Qty.

301 16D693 BLOCK, manifold, recirculation 1 302 262520 VALVE, drain, cartridge 2 303 156684 UNION; 1/2 in. m x f 2 304 112309 NUT, hex, jam 2 305 198241 PLUG, port, pressure; 11/16-24 2 306 156173 UNION, swivel; 3/8 fbe 2 307 114434 GAUGE, pressure, fluid, sst; 10k

psi 308 100840 FITTING, elbow, street; 1/4 npt 4 309 162453 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

306

r_258988_3a0420a_1b

Further tighten either valve (302) as required to line up handle straight across.

Apply grease to spring ends.

Torque to 70-90 in.-lbs (7.9-9 N•m).

Ref. No. Part No. Description Qty.

313 124859 SCREW, button hd 2 316 159239 FITTING, nipple; 1/2 x 3/8 npt 2 317 121399 O-RING, solvent resistant 2 318 124676 RING, snap, external 2 320 150829 SPRING, compression 2

3A0420H 47

Recommended Spare Parts

Keep these spare parts on hand to reduce downtime.

Pump Repair Kits

See page 11 to see what pumps are used on your sprayer model. 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

262520, Recirculation/Overpressure valve

15K692, Seal Mix Manifold Check Valve Cartridge

Mix Manifold Inlet Ball Valves

237917, Ball valve repair kit 248876, Spare valve (no handle) 237304, Spare valve (single handle)

248927, Spare Mix Elements (pack of 25)

248837, XTR7 Spray Gun Repair Kit

XHD010, Seat/Seal Kit for XHD RAC Tips (5 pack)

XHDxxx, spray tips

See spray gun manual for tips.

48 3A0420H

Pump Performance Charts

Calculate Fluid Outlet Pressure

To calculate fluid outlet pressure (psi/MPa/bar) at a specific fluid flow (gpm/lpm) and operating air pressure (psi/MPa/bar), use the following instructions and pump data charts.

1. Locate desired flow along bottom of chart.

2. Follow vertical line up to intersection with selected

fluid outlet pressure curve. Follow left to scale to read fluid outlet pressure.

1:1 or 2:1 Mix Ratio

8000

(56, 560)

7000

(49, 490)

6000

(42, 420)

5000

(35, 350)

4000

(28, 280)

3000

(21, 210)

Fluid Pressure in psig (MPa, bar)

2000

(14, 140)

1000

(7, 70)

Calculate Pump Air Flow/Consumption

To calculate pump air flow/consumption (scfm or

/min) at a specific fluid flow (gpm/lpm) and air pressure (psi/MPa/bar), use the following instructions and pump data charts.

1. Locate desired flow along bottom of chart.

2. Follow vertical line up to intersection with selected

air flow/consumption curve. Follow right to scale to read air flow/consumption.

200

(5.6)

180

(5)

160

(4.4)

140

(3.9)

120

(3.3)

100

(2.8)

(2.2)

(1.6)

(1.1)

(0.5)

Air Flow in SCFM (m

/min)

00.5

(1.9)

1.0

(3.8)

1.5

(5.7)

2.0

(7.6)

2.5

(9.5)

Fluid Flow in gpm (lpm)

Key:Air Pressure

A 95 psi (0.65 MPa, 6.5bar) B 70 psi (0.5 MPa, 7.8 bar) C 40 psi (0.3 MPa, 2.8 bar)

3A0420H 49

Pump Performance Charts

Pump Performance Charts Continued

1.5:1 Mix Ratio

Fluid Pressure in psig (MPa, bar)

8000

(56, 560)

7000

(49, 490)

6000

(42, 420)

5000

(35, 350)

4000

(28, 280)

3000

(21, 210)

2000

(14, 140)

1000

(7, 70)

200

(5.6)

180

(5)

160

(4.4)

140

(3.9)

120

(3.3)

100

(2.8)

(2.2)

(1.6)

(1.1)

(0.5)

Air Flow in SCFM (m

/min)

00.5

(1.9)

1.0

(3.8)

1.5

(5.7)

2.0

(7.6)

Fluid Flow in gpm (lpm)

Key:Air Pressure

A 80 psi (0.55 MPa, 55 bar) B 70 psi (0.5 MPa, 7.8 bar) C 40 psi (0.3 MPa, 2.8 bar)

2.5:1 and 3:1 Mix Ratio

Fluid Pressure in psig (MPa, bar)

8000

(56, 560)

7000

(49, 490)

6000

(42, 420)

5000

(35, 350)

4000

(28, 280)

3000

(21, 210)

2000

(14, 140)

1000

(7, 70)

2.5

(9.5)

200

(5.6)

180

(5)

160

(4.4)

140

(3.9)

120

(3.3)

100

(2.8)

(2.2)

(1.6)

(1.1)

(0.5)

Air Flow in SCFM (m

/min)

00.5

(1.9)

Key:Air Pressure

A 100 psi (0.7 MPa, 7 bar) B 70 psi (0.5 MPa, 7.8 bar) C 40 psi (0.3 MPa, 2.8 bar)

50 3A0420H

1.0

(3.8)

1.5

(5.7)

Fluid Flow in gpm (lpm)

2.0

(7.6)

2.5

(9.5)

Pump Performance Charts Continued

4:1 Mix Ratio

8000

(56, 560)

7000

(49, 490)

6000

(42, 420)

5000

(35, 350)

4000

(28, 280)

3000

(21, 210)

Fluid Pressure in psig (MPa, bar)

2000

(14, 140)

1000

(7, 70)

Pump Performance Charts

200

(5.6)

180

(5)

160

(4.4)

140

(3.9)

120

(3.3)

100

(2.8)

(2.2)

(1.6)

(1.1)

(0.5)

Air Flow in SCFM (m

/min)

00.5

(1.9)

1.0

(3.8)

1.5

(5.7)

2.0

(7.6)

2.5

(9.5)

Fluid Flow in gpm (lpm)

Key:Air Pressure

A 95 psi (0.65 MPa, 6.5bar) B 70 psi (0.5 MPa, 7.8 bar) C 40 psi (0.3 MPa, 2.8 bar)

3A0420H 51

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 an XP70 sprayer. 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, 119974

Heater Adapter Kit, 262450

Hose and fittings for connecting Viscon HP heaters to XP70 sprayer. See manual 406861 for parts. Purchase heaters separately, see heater manual for part numbers.

Twistork Agitator Kit, 256274

Remote Mix Manifold Carriage, 262522

A protective guard to mount mix manifold remote. See mix manifold manual for more information.

Gun Splitter, 234026

One splitter valve to use two spray guns with a proportioner. It can be used with one gun or two and provides for independent flushing of each gun while the other gun remains in use. See manual 309964 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.

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 a XP70 sprayer. See manual 312769 for more information.

For mixing viscous materials held within a 55-gallon drum. See manual 312769 for more information.

5:1 Feed Pump Kit, 256276

For supplying viscous materials from a drum to a XP70 sprayer. 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 a XP70 sprayer. 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 a XP70 sprayer. See manual 312769 for more information.

10:1 Drum Feed Kit, 256433

For supplying highly viscous material from a 55-gallon drum to a XP70 sprayer. See manual 312769 for more information.

52 3A0420H

Technical Data

Combined

Vol um e

Mix Ratio

1:1 76:1 Xtreme 85 Xtreme 85 173 95 (0.6, 6.5) 7250 (50, 500) 1.8 (6.9)

1.5:1 91:1 Xtreme 85 Xtreme 58 144 80 (0.5, 5.5) 7250 (50, 500) 1.5 (5.7) 2:1 76:1 Xtreme 115 Xtreme 58 174 95 (0.6, 6.5) 7250 (50, 500) 1.8 (6.9)

2.5:1 65:1 Xtreme 145 Xtreme 58 203 100 (0.7, 7) 6500, 45, 448) 2.1 (8.1) 3:1 68:1 Xtreme 145 Xtreme 48 193 100 (0.7, 7) 6800, 47, 469) 2.0 (7.7) 4:1 73:1 Xtreme 145 Xtreme 36 181 100 (0.7, 7) 7250 (50, 500) 1.9 (7.2)

Air inlet size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)

Air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 cfm at 100 psi inlet/gpm

Maximum air pressure supply to the sprayer . . . . . . . . . . . . . 175 psi (1 MPa, 12 bar)

Filtration:

Air inlet filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-micron filter/separator included

XP70 pump outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 mesh

XTR7 Spray Gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mesh

Fluid pump inlets without hoppers. . . . . . . . . . . . . . . . . . . . . . 1-1/4 in. npsm(m)

Fluid gauge manifold outlets . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 in. npt(f)

Fluid mix manifold inlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 in. npt(m) ball valves

Mix manifold material outlet . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 in. npt(f)

Maximum feed pressure from remote source . . . . . . . . . . . . . 250 psi (1.7 MPa, 17 bar)

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 15%

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)

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

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

Wetted 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

Flush pump suction tube. . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminum

Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nylon core

Weight:

Full System with heaters, solvent flush pump, and hoppers 575 lbs (260 kg)

Bare system with no heaters, solvent flush pump, or hoppers 425 lbs (192 kg) Maximum Storage Time: 5 years (To maintain original performance, replace soft seals

Maximum Lifetime: Indefinite with recommended maintenance and periodic

Power Efficiency Factor: 75 cu. ft compressed air/1 gallon sprayed material at 100 psi

Pressure

Ratio

“A” Side

Pump

“B” Side

Pump

Fluid Output

cc/cycle

Maximum Air

Working Pressure

psi (MPa, bar)

0.56 cu meter/min at 7 bar/liter/min

of outlet pressure

WPE, nylon, PTFE solvent resistant plastics

after 5 years of inactivity.)

rebuilds for critical parts.

0.56 m (7 bar)

compressed air /1 liter sprayed material at 0.7 MPa

Maximum Fluid

Working Pressure

psi (MPa, psi)

Flow Rate at

40 cycles/min

gpm (ltr/min)

3A0420H 53

Dimensions

Full SystemBare System

Top VIew

Side VIew

32 in.

(812.8 mm)

60 in.

(1524 mm)

52 in.

(1320.8 mm)

r_571100_3a0420_101a

35 in.

(889 mm)

r_571100_3a0420_100a

32 in.

(812.8 mm)

22 in.

(558.8 mm)

6.75 in.

(171.45 mm)

Floor Mounting Dimensions

54 3A0420H

15.25 in.

(387.35 mm)

40 in.

(1016 mm)

Top VIew

16.90 in.

(429.26 mm)

Bare Proportioner Mounting Hole Dimensions

The dimensions below is the minimum opening size for mounting a bare proportioner.

7.5in.

(190.5 mm)

Dimensions

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)

(128.52 mm)

3.75 in.

(95.25 mm)

2.25 in.

(57.15 mm)

9.25 in.

(234.95 mm)

5.06 in.

10.125 in.

(257.175 mm)

14.35 in.

(364.49 mm)

3A0420H 55

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

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

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 3A0420

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised 08/2011

Graco XP70 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Moisture Sensitivity of Isocyanates

Foam Resins with 245 fa Blowing Agents

Changing Materials

A and B Component Designations

Overview

Usage

Over Pressure Protection

Initial System Setup

Models

Cart-Mounted XP70 Sprayers

Bare Proportioning Pump Packages

Component Identification

Fluid Control Assembly

Main Air Controls

45:1 Solvent Flush Pump Kit 262393 (optional)

Air Line

Fluid Line Accessories

Flush Before Using Equipment

Setup

Location

Grounding

Wire Sprayers with Explosion-Proof Heaters

Air Motor Position

Connect Air Supply

Connect Fluid Hose Bundles (Remote Only)

Connect Static Mixers, Gun, and Hoses

Pressure Relief Procedure

Prime Empty Sprayer

Prime A and B Fluids

Prime Solvent Flush Pump

Recirculate or Re-Prime After a Pump Runs Dry

Spray

B Side Mix Manifold Restriction

Flush Mixed Material

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

Shutdown

Park

System Verification

Maintenance

Filters

Seals

Recommended Spare Parts

Change the Mix Ratio

Cleaning Procedure

Troubleshooting

Pump Troubleshooting

Repair

Pump Assembly

Air Controls

Mix Manifold Assembly

Fluid Circulation Manifold

Hoppers

Solvent Pump

Optional Fluid Heaters

Parts

Cart-Mounted XP70 Sprayer

Bare Proportioning Pump Package

Air Controls, 258983

Fluid Manifold, 258990

Recommended Spare Parts

Pump Performance Charts

Calculate Fluid Outlet Pressure

Calculate Pump Air Flow/Consumption

Accessories and Kits

Acceptable For Use in Explosive Atmospheres

Not Approved For Explosive Atmospheres

Technical Data

Dimensions

Bare Proportioner Mounting Hole Dimensions

Graco Standard Warranty