Hitachi MIX 309521J User Manual
Installation - Parts
™
Xtreme Mix
Plural Component Mixer, OEM Unit
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 4 for model information, including maximum working pressure and approvals.
OEM
309521J
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
Contents
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Xtreme Mix OEM Models . . . . . . . . . . . . . . . . . . . . . 4
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 7
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pumps and Sensors . . . . . . . . . . . . . . . . . . . . . . 9
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Proper Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operation and Repair . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . 16
Pneumatic Schematic . . . . . . . . . . . . . . . . . . . . . . 18
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Xtreme Mix Proportioner . . . . . . . . . . . . . . . . . . 20
Pneumatic Control 245803 . . . . . . . . . . . . . . . . 22
User Interface 245804 . . . . . . . . . . . . . . . . . . . . 24
Pump Air Manifold 245802 . . . . . . . . . . . . . . . . 25
Metering Valve Manifold 245824 . . . . . . . . . . . . 26
Sampling Valve 245143 . . . . . . . . . . . . . . . . . . . 26
Metering Valve 245846 . . . . . . . . . . . . . . . . . . . 27
Fluid Manifold 245833 . . . . . . . . . . . . . . . . . . . . 28
Sensor 245825 . . . . . . . . . . . . . . . . . . . . . . . . . 29
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 32
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 309521J
Manual Conventions
Warning Caution
Manual Conventions
WARNING
A warning alerts you to possible serious injury or
death if you do not follow instructions.
Symbols, such as fire and explosion (shown), alert you
to a specific hazard and direct you to read the indicated hazard warnings (pages 5-6).
CAUTION
A caution alerts you to possible equipment damage or
destruction if you do not follow instructions.
Note
A note indicates additional helpful information.
Related Manuals
Refer to the following manuals for detailed component information.
Component Manuals This manual available in following languages:
Manual Description
309535 Xtreme Mix Operation
309518 Xtreme Mix Repair
311762 Xtreme Displacement Pump
309347 King Air Motor
or 309348 King Quiet Air Motor
312145 XTR Spray Gun
309524 VISCON HP Heater
309525 Heated Hose Kit
308981 Husky 716 Diaphragm Pump
309615 Heater Bracket Kit
309568 Remote Manifold Kit
Manual Language Manual Language
309521 English 309540 German
309538 French 309546 Swedish
309539 Spanish 309604 Japanese
309521J 3
Xtreme Mix OEM Models
WARNING
Do not install equipment approved only for non-hazardous location in a hazardous area. Substitution of
components may impair intrinsic safety. See page 5.
Approved for Hazardous Location
Class I, Div 1, Group D
Xtreme Mix OEM Models
Xtreme
Mix
Part No. Series
Pump
Part No.
Pump
Description
Maximum Working
Pressure
psi (MPa, bar) Approvals
233871 A 249274 45:1 King 4500 (31, 310)
233872 A 249275 56:1 King 5600 (38.6, 386)
233873 A 249276 68:1 King 6800 (46.9, 469)
233874 A 249277 80:1 King 7250 (50, 500)
233875 A 249278 45:1 Quiet King 4500 (31, 310)
233876 A 249279 56:1 Quiet King 5600 (38.6, 386)
233877 A 249280 68:1 Quiet King 6800 (46.9, 469)
233878 A 249281 80:1 Quiet King 7250 (50, 500)
234024 A none
Approved for Non-hazardous Location
233879 A 249274 45:1 King 4500 (31, 310)
233880 A 249275 56:1 King 5600 (38.6, 386)
233881 A 249276 68:1 King 6800 (46.9, 469)
233882 A 249277 80:1 King 7250 (50, 500)
233883 A 249278 45:1 Quiet King 4500 (31, 310)
233884 A 249279 56:1 Quiet King 5600 (38.6, 386)
233885 A 249280 68:1 Quiet King 6800 (46.9, 469)
233886 A 249281 80:1 Quiet King 7250 (50, 500)
234025 A none
Conforms to
FM std 3600 & 3610 for
use in Class I Div 1
Group D
T3 Hazardous locations
Conforms to UL std 61010A-1
CSA std C22.2 No 1010.1-92
CAN/CSA
22.2 No. 157-92
& No. 1010.1-92
ll 2 G
4 309521J
Xtreme Mix OEM Models
Warning
Skin Injection Hazard
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point the gun at anyone or at any part of the body.
• Do not put your hand or fingers over the gun fluid nozzle.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not “blow back” fluid; this is not an air spray system.
• Follow Pressure Relief Procedure, page 7, when you stop spraying and before cleaning, checking,
or servicing equipment.
• Use lowest possible pressure when flushing, priming, or troubleshooting.
• Never spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. High pressure hose cannot be recoupled; replace the entire hose.
Fire and Explosion Hazard
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 and plastic drop cloths (potential static
arc).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep the work area free of debris, including solvent, rags, and gasoline.
• Ground equipment and conductive objects. See Grounding, page 11.
• Hold gun firmly to side of grounded pail when triggering into pail.
• Use only grounded hoses.
• If there is static sparking or you feel an electric shock, stop operation immediately. Do not use
equipment until you identify and correct the problem.
• If connecting PC for data download, PC must be in non-hazardous location and a safety barrier must
be installed. See Xtreme Mix software documentation.
• Keep a fire extinguisher in the work area.
Electric Shock Hazard
Improper grounding, wiring, or usage of the system can cause electric shock.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
• Connect only to grounded power source.
• Turn off and disconnect power at the main switch before disconnecting any cables and before servicing equipment.
309521J 5
Xtreme Mix OEM Models
Warning
Moving parts hazard
Moving parts can pinch or amputate fingers and other body parts. Pressurized equipment can start accidentally and cause serious injury.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Before checking or servicing equipment, follow Pressure Relief Procedure, page 7. Disconnect
power or air supply.
• Do not move or lift pressurized equipment.
Equipment Misuse Hazard
Misuse can cause serious injury or death.
• For professional use only.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Read manuals, warnings, tags, and labels before operating equipment. Follow instructions.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not alter or modify equipment. Use only Graco parts and accessories.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-
ponent. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or overbend hoses or use hoses to pull equipment.
• To lift equipment, follow instruction, page 15.
• Comply with all applicable approval requirements and safety regulations.
Burn Hazard
This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To
avoid severe burns:
• Do not touch hot fluid or equipment.
• Allow equipment to cool completely before touching it.
• Wear gloves if fluid temperature exceeds 110° F (43° C).
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 Material Safety Data Sheet (MSDS) to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
Personal Protective Equipment
You must wear proper protective equipment when operating, servicing, or when in the operating area of
the equipment to help protect you from serious injury, including eye injury; inhalation of toxic fumes; and
hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Gloves, clothing, and respirator as recommended by the fluid and solvent manufacturer
• Hearing protection
Recoil Hazard
The gun can recoil when triggered at a very high pressure. If unprepared, this could force your hand back
or cause you to fall and injure yourself. Be sure you have firm footing and hold the gun securely.
6 309521J
Pressure Relief Procedure
Pressure Relief Procedure
WARNING
Follow Pressure Relief Procedure when you stop
spraying and before cleaning, checking, servicing, or
transporting equipment. Read warnings, page 5.
1. Engage trigger lock.
2. Press Stop .
SUPPLY AIR
PRESSURE
I
O
PLURAL COMPONENT PROPORTIONER
3. Close main air shutoff valve on air supply line and on
unit. Turn off air regulator.
4. Close fluid sampling and shutoff valves A and B.
6. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger gun to relieve pressure.
7. Engage trigger lock.
8. Place waste container under sampling valves, then
open valves A and B slowly to relieve pressure
between pump and metering valves.
Open
Close
Open
Close
AB
PSI
Bar
MPa
Close
Close
PSI
Bar
MPa
I
O
AB
Close
Close
9. Close sampling valves A and B.
Close Close
5. Disengage trigger lock.
AB
309521J 7
Assemble
2
913913
910
911
10
Assemble
5
901
904
905
914
915
721
3
307
912
903
7
6
4
902
FIG. 1
8 309521J
Assemble
Pumps and Sensors
• If using feed pumps, do not allow feed pressure
to exceed 25% of spray pressure.
• For accurate ratios, pump lowers must be
same size.
• If installing 234024 or 234025, the pump size
has not been set in the software. To set pump
A and B size and A and B sensor calibration
factors, you need Xtreme Mix Data Download
software, part no. 246322 for proportioners
located in a non-hazardous area, or part no.
246397 for proportioners located in a hazardous area.
Calibration values are on pump A and B sensors.
Pump Size Values
Pump Size Value
(cc/cycle)
45:1 250
56:1 220
68:1 180
80:1 145
1. Secure magnet holders (903) to the pump (2) motor
displacement rods with screws (905). F
2. Install a short magnet strip then a long one (904) on
each magnet holder (903). Secure with tape supplied.
3. Secure pumps (2) on mounting brackets with two
3/8 x 1-1/4” screws (913), lockwashers (914), and
nuts (915).
4. Secure sensors (7) on pumps and pump mounting
brackets with two screws (913), lockwashers (914),
and nuts (915).
IG. 1.
Control Box
1. Mount control box (3) to mounting plate (10). FIG. 1.
a. Slide gasket (307) over back of pneumatic con-
trol box (3), against lip. Insert box through
mounting plate (10).
b. Secure box (3) to plate (10) with 8-32 UNC
screws (912).
Mount box (3) vertically for optimum alternator and
component life.
2. Secure mounting plate (10) to cart/stand. Install fasteners (provided by installer) through six 0.3” (7.62
mm) mounting plate holes.
3. Connect conduit (721) from two sensors (7) to pneumatic control box (3).
Conduit must be used. Approximately 62” (1575
mm) of cable and conduit provided; do not
lengthen.
4. Wire two sensors (7) to control box 18-pin connector. Connect sensor A, then sensor B wires in pairs
sequentially – black/green, black/red, black/white –
to pins 2-13. See Electrical Schematic, page 16.
5. Connect 18-pin connector to main control board
connector (F). F
3
IG. 2.
10 9 8 7 6 5 4 3
J2
5
3
4
F
J1
6
10
9
7
8
-
+
F
IG. 2 Control Box
309521J 9
Assemble
A
33
B
2
3
2
501
C
F
G
1
H
J
D
E
5
K
Key:
A Pump A Air
B Pump B Air
C Pump A Pilot Air
D Pump B Pilot Air
E Air Supply
F Metering Valve A - CLOSE
G Metering Valve A - OPEN
H Metering Valve B- CLOSE
J Metering Valve B- OPEN
K Sensor A Cable
L Sensor B Cable
2Pump
FIG. 3
902
6
901
L
3 Pneumatic Control
6 Metering Valve Manifold
501 Pneumatic Valve
901 Air Filter
902 Ground Wire Assembly
1
Ground manifold to true earth ground.
2
Ground by connecting ground wire from control box (3) to
manifold (6).
3
Ground by connecting ground wire from pumps (2) to
manifold (6).
10 309521J
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