Graco 3A2989G Xm Pfp Users Manual 3A2989G, PFP, Repair Parts, (English)

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Repair - Parts

XM PFP

3A2989G
EN

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

Important Safety Instructions
Read all warnings and instructions in all
supplied manuals. Save all instructions.
See page 3 for model information, including
maximum working pressure and approvals.

WLD

Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Keep Components A and B Separate . . . . . . . . 6
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 6
Components A and B . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Replace Air Filter Element . . . . . . . . . . . . . . . . . 9
User Interface/Control Box . . . . . . . . . . . . . . . . 10
Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Dosing Valve Assembly . . . . . . . . . . . . . . . . . . 19
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pump Assembly (System Module) . . . . . . . . . . 21
Pail Feed RAM Pump Assembly (Feed Module) 22
Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Replace Radar Level Sensor . . . . . . . . . . . . . . 24
Set Up a New Guided Radar Level Sensor . . . 25
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 27
Simplified Electrical Schematic . . . . . . . . . . . . . 27
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
XM PFP System (262869, 24W626) . . . . . . . . . 32
Base System (262878, 24W648) Subassemblies 44
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 62
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 62

2

3A2989G

Models

Models
Models

Maximum Fluid
Working Pressure

Maximum Air Working
Pressure

Approvals

A and B Materials:
6000 psi
(41 MPa, 414 bar)
262869
24W626

Flushing Fluid:
4500 psi
(31 MPa, 310 bar)

Supply: 150 psi
(1.0 MPa, 10.3 bar)
Max. Setpoint: 100 psi
(0.7 MPa, 7 bar)

Heating Fluid:
100 psi
(0.7 MPa, 7 bar)

9902471
Certified to CAN/CSA C22.2 No. 88
Conforms to
UL 499

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

Manual

Description

Accessories

Manual

Description

332073

Hot Water Flush Kit Instructions

3A2776

XM PFP Setup - Operation

3A2987

Air Dryer Kit Instructions

3A2988

XM PFP Mix Manifold Instructions - Parts

3A2799

XHF Spray Gun

Heaters
Viscon®

3A2954

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

3A2824

Viscon LT Fluid Heater Instructions - Parts

309524

Pumps, Motors, Supply Systems
308652

Husky™ 205 Air-Operated Diaphragm
Pumps Instructions - Parts

311238

NXT® Air Motor Instructions - Parts

311762

Xtreme® Lowers Instructions - Parts

312376

Check-Mate® Displacement Pumps
Instructions - Parts
Check-Mate Pump Packages Instructions Parts

312792

Merkur® Pump Repair - Parts

312794

Merkur Pump Assembly Instructions - Parts

312796

NXT Air Motor Instructions - Parts

313526

Supply Systems Operation

313527

Supply Systems Repair - Parts

312374

Air Control Instructions - Parts

312375

3A2989G

Other
313342

Dosing Valve Instructions - Parts

306861

Ball Valves Instructions - Parts

307005

High Pressure Swivel Instructions - Parts

308169

Air Filters, Lubricators, and Kits Instructions
- Parts

407061

Simulation XM PFP Display Module

3A1244

Graco Control Architecture Module Programming

3

Warnings

Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.

WARNING
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.

4

3A2989G

Warnings

WARNING
WARNING
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is
not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer
SPLATTER HAZARD
Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen,
splatter may occur.
• Use minimum air pressure when removing platen from drum.

3A2989G

5

Component Identification

Keep Components A and B
Separate

Component Identification
See XM PFP Operation manual for component identification.

Cross-contamination can result in cured material in
fluid lines which could cause serious injury or damage
equipment. To prevent cross-contamination:
• Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been contaminated from the other side.

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

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

•

Always clean any fluid inlet strainers after flushing.

•

Check with your material manufacturer for chemical
compatibility.

•

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

Grounding

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

Components A and B
IMPORTANT!
Material suppliers can vary in how they refer to plural
component materials.
Be aware that in this manual:
Component A refers to resin or major volume.
Component B refers to the hardener or minor volume.

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

6

3A2989G

Pressure Relief Procedure

Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.

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

NOTICE
The material may expand when air pressure is
removed. This can cause the tank to overfill and
damage the parts attached to the tank lid. To prevent overfilling the tank, never relieve air pressure
in the tank unless the tank is less than half full.
Verify tank material level on the user interface, see
Appendix A - User Interface Display section in
XM PFP Operation manual.
5. If necessary to relieve tank air pressure: close both
feed system air control ball valves and back out the
air pressure regulator. Open the brass valves on the
tank lids for full tank de-pressurization. Pressure
gauge should read 0 psi.

FEED PUMP
BYPASS

TI19265a2

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

FIG. 2

(Stop button).

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

DF

ti20127a

6. Open mix manifold ball valves.

DE
DC

DD

DB

DA

ti20128a
ti20104a

FIG. 1: Feed Pump Controls

3A2989G

7

Troubleshooting

7. Open recirculation ball valves.

11. Close mix manifold material ball valves.

ti20129a

WLD

8. Disengage trigger lock.

12. Perform Flush Mixed Material procedure in XM
PFP Operation manual to prevent mixed material
curing in the system and to relieve pressure in the
solvent lines.
13. Close metering pump air supply ball valve.

TI19265a1

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

14. If the system will be shutdown for more than a few
hours, fill pump A and B packing nuts with throat
seal liquid (TSL™).
TI1953a

10. Engage trigger lock.

NOTE: Fluid pressure in the system is now relieved.

Troubleshooting
See XM PFP Operation manual 3A2776 for troubleshooting details.

TI19265a2

8

3A2989G

Repair

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

3. Unscrew filter bowl from inlet air regulator (601d).
4. Remove and replace element.
601d

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

r_312359_313289_15

Replace Air Filter Element

5. Screw filter bowl on securely.

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

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

Main Air Inlet Manifold Filter
2. Unscrew filter bowl collar from main air inlet
filter (14).

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

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

Control Air Regulator Filter

14

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

21

ti199526a1

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

20
19

ti19926a1

3A2989G

9

Repair

User Interface/Control Box

2. Disconnect solenoid cable connector (542) from the
solenoid (509a) being replaced.
3. Remove two screws (509b) from the solenoid being
replaced then remove solenoid (509a). See FIG. 4.

Remove Shroud and Front Panel of Control
Box
1. Close main air shutoff valve on air supply line and
on system. Depressurize air line.
2. Remove four nuts (21) and then remove front and
rear shrouds (19, 20).
509b
21

r_xm1a00_312359_313289_9_3

509a
20

FIG. 4

19
4. Use screws (509b) to install new solenoid (509a).
5. Reconnect solenoid cable connectors (542). See
Control Box (255771) on page 47.

ti19926a1

3. Disconnect power.

NOTE:

4. Remove four nuts (17); leave two nuts on left side of
panel tight. Open front panel of control box (16).
See FIG. 3.

From left to right, solenoid functions are as follows:
• Dosing valve A (DVA) (normally open)
• Dosing valve B (DVB) (normally open)
• Pump A (PA) (normally closed)
• Pump B (PA) (normally closed)

17
16
DVA

DVB
PA
PB

r_xm1a00_312359_313289_9_3

ti20158b1

FIG. 3

Replace Single Solenoid Module
1. Remove Shroud and Front Panel of Control Box,
see page 10.

10

3A2989G

Repair

Update USB Module Software

Replace USB Module

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

1. Remove Shroud and Front Panel of Control Box,
see page 10.
2. Disconnect CAN cables and USB cable from USB
module (519).

21

19

ti19926a1

2. Use software token 16P644. See Graco Control
Architecture™ Module Programming manual for
instructions.
NOTE: Upgrade all modules in the system to the
software version on the token, even if you are
replacing only one or two modules. Different software versions may not be compatible.
All data in the module may be reset to factory
default settings. Record all settings and user preferences before the upgrade, for ease of restoring
them following the upgrade.

r_312359_313289_23a

20

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

519

4. Follow steps in reverse order to install new USB
module.
5. Load software. See Update USB Module Software.

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

3A2989G

11

Repair

Update Fluid Control Module (FCM)
Software

3. Loosen four mounting screws (535).
r_312359_313289_26

518

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

535

21
535
20
19
4. Slide FCM up and out of keyhole slots.
ti19926a1

2. Use software token 16P644. See Graco Control
Architecture™ Module Programming manual for
instructions.
NOTE: Upgrade all modules in the system to the
software version on the token, even if you are
replacing only one or two modules. Different software versions may not be compatible.

5. Follow steps in reverse order to install new FCM.
6. Load software. See Update Fluid Control Module
(FCM) Software.
7. Most of the system configuration is stored in the
FCM. Use the display to change the configuration to
the values in the old FCM. See XM PFP operation
manual for instructions.

Replace Alarm

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

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

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

3. Unscrew alarm (517) and replace.

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

r_312359_313289_22

Replace Fluid Control Module (FCM)

2. Disconnect alarm wires from alarm (517).

1. Remove Shroud and Front Panel of Control Box,
see page 10.
2. Remove all cables from FCM (518). Take note of
cable locations.

517

4. Screw in new alarm. Reconnect alarm wires.
5. Reinstall front panel of control box and reinstall
shrouds.

12

3A2989G

Repair

Display

6. Turn power off.

Upgrade Software

7. Remove token (T).

NOTICE
To avoid damaging circuit board, wear a grounding
strap.

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

Use software token 16P644. See Graco Control Architecture™ Module Programming manual for instructions.
NOTE: Upgrade all modules in the system to the
software version on the token, even if you are
replacing only one or two modules. Different software versions may not be compatible.
All data in the module may be reset to factory
default settings. Record all settings and user preferences before the upgrade, for ease of restoring
them following the upgrade.
The latest software version for each system can be
found at Tech Support at www.graco.com.

Replace Display Battery
NOTICE
To avoid damaging circuit board, wear a grounding
strap.
1. Perform steps 1-2 in the Upgrade Software section
on page 13.
2. Use a flat head screwdriver to pry out old battery.
Remove Old Battery

Insert New Battery

Connector
Tabs
r_xm1a00_312359_313289_9_8a

1. Remove Shroud and Front Panel of Control Box,
see page 10.
2. Remove four screws (512) then remove access
cover (511).

3. Replace with new battery. Ensure battery fits under
connector tabs before snapping other end in place.
NOTE:
Use only Panasonic CR2032 batteries for replacement.
4. Use screws (512) to install access cover (511).

512
Battery
L

511

T
r_xm1a00_312359_313289_2a

3. Insert and press token (T) firmly into slot.
NOTE:
There is no preferred orientation of token.
4. Turn power on.
5. The red indicator light (L) will flash until new software is completely loaded.

3A2989G

13

Repair

Replace Display

6. Discard old display assembly.

NOTE: Order display kit 257484 for replacement.

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

NOTICE
To avoid damaging circuit board, wear a grounding
strap.

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

1. Remove Control Box Shrouds, see page 17.
2. Disconnect CAN cable from display module.

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

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

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

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

10. Install access cover and screws. Apply warning
label to access cover.
11. Reconnect CAN cable to display module.
r_312359_313289_24a

507

12. Reconnect power.
13. Load software. See Upgrade Software, page 13.
14. Replace shroud.
15. Configure system settings as they were set on old
display. See XM PFP Operation manual for instructions.

505

506

Replace Front Panel
See Replace Display, page 14, for instructions.

4. Remove rear display panel (505) and disconnect
display cable and key switch cable (539) from circuit
board.
5. Remove front display panel (507) and gasket (513).
Display Cable

539

r_xm1a00_312359_313289_25a

507

14

513

506

505

3A2989G

Repair

Junction Box

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

Update High Power Temperature Control
Module (HPTCM, ref. 404) Software
NOTE: Upgrade all modules in the system to the
software version on the token, even if you are
replacing only one or two modules. Different software versions may not be compatible.
All data in the module may be reset to factory
default settings. Record all settings and user preferences before the upgrade, for ease of restoring
them following the upgrade.
The latest software version for each system can be
found at Tech Support at www.graco.com.
1. Open junction box.

ti21595a

404

B

HOSE

1. Turn system main power switch OFF.
2. Open junction box.

A

3. Unplug all connections on the HPTCM.
4. Remove screws securing HPTCM then remove
HPTCM.

ti20155a

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

2. Use software token 16P644. See Graco Control
Architecture™ Module Programming manual for
instructions.

ti12360a

6. Use screws to install HPTCM.
7. Reattach HPTCM connections.
8. Close junction box.

3A2989G

15

Repair

Update Fluid Control Module Cube (FCM3,
ref. 415) Software
NOTE: Upgrade all modules in the system to the
software version on the token, even if you are
replacing only one or two modules. Different software versions may not be compatible.
All data in the module may be reset to factory
default settings. Record all settings and user preferences before the upgrade, for ease of restoring
them following the upgrade.
The latest software version for each system can be
found at Tech Support at www.graco.com.
415

B

HOSE

3. Unplug all connections on the FCM3.
4. Remove two screws securing FCM3 then remove
FCM3.

Center ground screw in the Fluid Control Module
Cube must be used to avoid serious injury due to
electric shock.
5. Use screws to install FCM3.
6. Reattach FCM3 connections.
7. Perform Update Fluid Control Module Cube
(FCM3, ref. 415) Software on page 16.

A

8. Close junction box.

ti20155a

1. Open junction box.
2. Use software token 16P644. See Graco Control
Architecture™ Module Programming manual for
instructions.

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

Ground screw

ti21594a

1. Turn system main power switch OFF.
2. Open junction box.
16

3A2989G

Repair

Air Controls
Remove Control Box Shrouds
1. Close main air shutoff valve on air supply line and
on system. Depressurize air line.
2. Remove four nuts (21) and then remove front and
rear shrouds (19, 20).

8. Follow steps in reverse order to reassemble.

Replace Solvent Air Regulator
1. Remove Control Box Shrouds.
2. Disconnect air motor air lines and system air line.
3. Remove four nuts (17) from front of air controls (18).
See page 36.
4. Pull out assembly.

21
20
19

ti19926a1

Remove Air Control Assembly
1. Remove Control Box Shrouds.
2. Disconnect air motor air lines and system air line.
3. Remove four nuts (17) from front of air controls (18).
See page 36.
4. Pull out assembly.
5. Follow steps in reverse order to reinstall air control
assembly.

Replace Solvent Pump Air Ball Valve
1. Remove Control Box Shrouds.

5. Remove regulator nut (631), and disconnect air
lines (632, 633) running to regulator (625). See FIG.
5 on page 18.
6. Remove regulator assembly and replace with new.
See part number shown in the System Air Controls Module (255761) section beginning on
page 44.
7. Follow steps in reverse order to reassemble.

Replace System Air Regulator
1. Remove Control Box Shrouds.
2. Disconnect air motor air lines and system air line.
3. Remove four nuts (17) from front of air controls (18).
See page 36.
4. Pull out assembly.
5. Remove regulator nut (601h) and disconnect system air line.
6. Remove screws from quick clamps and open
clamps (601f) at hinge.

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

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

4. Pull out assembly.

8. Follow steps in reverse order to reassemble.

5. Remove two nuts (630) from front of air control
bracket (619). See FIG. 5 on page 18.

Replace Solenoid Inlet Air Regulator

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

6. Disconnect air line (632) running to ball valve
assembly (626).
7. Replace with new ball valve assembly. See part
number shown in the System Air Controls Module
(255761) section beginning on page 44.

3A2989G

1. Remove Control Box Shrouds.
2. Disconnect air motor air lines and system air line.
3. Remove four nuts (17) from front of air controls (18).
See page 36.
4. Pull out assembly.

17

Repair

5. Disconnect air line.

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

6. Remove gauge (606) from block (601e).
7. Remove screws from quick clamps (601f) holding
air regulator assembly (601c) in place.

10. Follow steps in reverse order to reassemble.

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

11. Set new air pressure regulator to at least 80-85 psi
(0.55-0.58 MPa, 5.5-5.8 bar).

616

617

644

607

608
613
610

603

611
609

Ref. 27

615

645
642

626
619

637

636

638

632

629

612

632

613

635
617
646

643
618

606

625
628

630
627
640 631

627

635

629
634
633

642
621

622

633

647

604
641

620

618

FIG. 5

18

3A2989G

Repair

Dosing Valve Assembly

1. Follow Pressure Relief Procedure, page 7.

6. Remove dosing valves.

2. Disconnect all fluid lines from dosing valves (28 or
29). See FIG. 6.

7. See Ratio Control Valve Assemblies on page 50
for disassembly illustration.

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

8. Follow steps in reverse order to reassemble dosing
valve assembly. See Ratio Control Valve Assemblies on page 50 for assembly illustration and specifications.

4. Unscrew dosing valve nipple fitting (36 or 37) from
dosing valve outlet.
5. Disconnect pressure sensor (831) from dosing
valve. See page 50.
29

28
55

85

37
36
55

54

31

FIG. 6

3A2989G

19

Repair

Sensors

Replace Temperature (RTD) Sensors
This procedure applies to:
•

Tank sensors mounted in the side of each tank near
the bottom (209).

Replace Fluid Pressure Sensor

•

Glycol heater for hose outlet manifold sensor (100).

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

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

2. Follow Pressure Relief Procedure, page 7.

2. Follow Pressure Relief Procedure, page 7.

3. Open control box cover. See User Interface/Control Box, page 10.

3. Disconnect the M8 cable connection.

4. Disconnect pressure sensor (831) from dosing
valve. See Ratio Control Valve Assemblies on
page 50.
5. Disconnect other end of pressure sensor (831) from
FCM (518). See Control Box (255771) on page 47.
6. Replace with new fluid pressure sensor, and reconnect pressure sensor to FCM and dosing valve.

Hose Bundle Temperature Sensor (93)
1. Disconnect the M8 cable connection going into the
hose bundle.
2. Open up the hose bundle wrap and insulation until
sensor (93) can be removed easily without pulling
on cable.
3. Remove sensor.

4. Loosen the compression nut. Pull sensor straight
out of fitting.
5. Remove fitting (82 or 208).
NOTE: The compressed ferrule cannot be removed
from the sensor. A new compression fitting must be
used.
6. Apply thread sealant then replace compression
fitting (82 or 208). Tighten fitting in place.
7. Position sensor (100 or 209):
•
•

Tank: Insert sensor, leaving 5/8 in. sheath outside fitting.
Heater manifold: Insert sensor, leaving 1/8 in.
sheath outside fitting.

8. Install compression nut on sheath hand-tight then
tighten an additional 3/4 turn.

4. Push new sensor fully into insulated portion of hose
bundle.
5. Close insulation and hose bundle wrap and re-tape.
Ensure there is no stress on the cable.
6. Reconnect M8 connector.

20

3A2989G

Repair

Pump Assembly (System
Module)

Remove Displacement Pump
Follow these instructions for removing only the displacement pump; the air motor will remain installed.
1. Follow Pressure Relief Procedure, page 7.
2. Close ball valve on tank outlet.

Prior to servicing the pump assembly you must first
remove either the entire pump assembly or the displacement pump and air motor individually.

Remove Pump Assembly

3. Disconnect fluid inlet line from the displacement
pump. Leave line connected to the tank.
4. Remove clip (2b), and slide coupling cover (2c) up
to remove coupling (2a).
2c

1. Follow Pressure Relief Procedure, page 7.
2. Close ball valve at metering pump inlet.
3. Disconnect fluid inlet line from the displacement
pump. Leave line connected to the tank.

2a
2b

4. Disconnect air motor.
a. Disconnect sensor cable, air line, and ground
wire from air motor.
b. Remove mounting screws (5) and washers (4)
holding air motor (2 or 3) to mounting bracket.
See FIG. 7 on page 22.

ti8264a

5. Use a wrench to hold the tie rod flats to keep the
rods from turning. Unscrew the nuts (2e) from the tie
rods (2d) and carefully remove the displacement
pump (2f).
2d

5. Use lift ring on air motor to remove pump assembly.

2f
To avoid serious injury from falling objects caused by
the lift ring breaking, do not lift pump assembly by the
lift ring when the total weight of the pump assembly
exceeds 550 lb (250 kg).
6. Refer to Xtreme Displacement Pump manual
311762 to service or repair the displacement pump.
Refer to NXT Air Motor manual 311238 to service or
repair the air motor.

2e
ti8301a

6. Refer to the Xtreme Displacement Pump manual
311762 to service or repair the displacement pump.
7. Follow steps in reverse order to reinstall displacement pump.

7. Follow steps in reverse order to reinstall pump
assembly.

3A2989G

21

Repair

Solvent Pump

Remove Air Motor
1. Follow Pressure Relief Procedure, page 7.
2. Disconnect displacement pump from air motor. See
steps 2 and 3 under Remove Displacement Pump,
page 21.
3. Disconnect sensor cable, air line, and ground wire
from air motor.
4. Remove mounting screws (5) and washers (4) holding air motor (2 or 3) to mounting bracket.

2 or 3

1. Follow Pressure Relief Procedure, page 7.
2. Disconnect pump inlet line (154) and air lines (57,
60) from solvent pump.
3. Disconnect fluid outlet line.
4. Remove four screws (153) that attach solvent
pump (8) to bracket (152) and remove solvent
pump.
152

153

8

Bracket
4
57
5
r__312359_313289_32

60

FIG. 7
154
5. Refer to NXT Air Motor manual 311238 to service or
repair the air motor.
6. Follow steps in reverse order to reinstall air motor.

Pail Feed RAM Pump Assembly
(Feed Module)

5. Refer to Merkur Pump Assembly manual 312794 to
service or repair solvent pump 257463.
6. Follow steps in reverse order to reinstall solvent
pump.

NOTE: See Pail Feed RAM Pump assembly (227) in
parts breakdown beginning on page 40.
See Supply Systems manual 313527 for service and
repair instructions and parts.

22

3A2989G

Repair

Heaters

Replace
1. Follow Pressure Relief Procedure, page 7.
2. Disconnect fluid lines and electrical wiring from fluid
heater.

NOTE:
See applicable heater manual for wiring, repair, and
parts information. See Related Manuals on page 3.

Service and Repair
1. Follow Pressure Relief Procedure, page 7.
2. Disconnect fluid lines and electrical wiring from fluid
heater.
3. Refer to heater manual to service or repair heater.

3. System Module Heaters: See FIG. 8. Loosen four
mounting screws, lock washers, and plain washers
on back of heater (12 or 13) that secure it to the system frame. Slide heater up and remove from mounting plate.
4. Feed Module Heaters: See page 41. Remove 2
screws (224) then remove heater (226) from feed
module frame.
5. Replace heater. Follow steps in reverse order to
install new heater.

4. Reconnect fluid lines and electrical wiring.

12

13

12
FIG. 8: Heaters on System Module

3A2989G

23

Repair

Replace Radar Level Sensor

NOTE: Order radar level sensor kit 24T052. See Feed
Module (24P883) on page 40 for kit contents.

8. Use a wrench to hold the 3/8 in. flats on the sensor
rod.

NOTE: Tank level sensors changed in 2014. The old
sensors were red. The new sensors are blue. The blue
sensors can be used as direct replacements for the red
sensors.

9. Tighten to approximately 25 - 30 in-lb (2.8 - 3.4
N•m). Do not over-tighten.

1. With the tank empty, close the tank air supply ball
valve then open brass valve on tank lid to de-pressurize the tank. See FIG. 9.

10. Reconnect sensor cable.
11. See Set Up a New Guided Level Sensor, page 25.

Tank Air
Supply Ball
Valve location
(on other side
of panel)

Valve

WLD

FIG. 9: Level Sensor Installation
2. Disconnect cable at the bottom of the feed module.
NOTE: Always use the new cable supplied with the
sensor. It has different connections than the old
sensor.
3. Disconnect 3/4 in. union that holds the level sensor
on top of the tank.
4. Pull the old sensor straight up out of the tank.
5. Remove plugs from new sensor and discard plugs.
Move fittings from old sensor to new sensor.
6. If the sensor rod was removed for shipping, apply
blue thread-lock to the threads in the end of the rod.
7. Feed the rod into the sensor head and screw the
threaded end into the sensor head.

24

3A2989G

Repair

Set Up a New Guided Radar Level Sensor
Level sensors need to have three settings setup after installing on the tank of the PFP machine. The tank must be
empty, or the level needs to be at least below the bottom of the installed probe with the tank cover closed.
1. Open the sensor head cover over the display:
a. Loosen the securing clamp with an Allen wrench (if clamp is present).
b. Unscrew the round cover and pull away.

ti24380a

Use the operating keys to navigate within the operating menu and to select options from a list.
Key

Meaning
“Minus” Key

• In a selection list, this key will move the selection bar upward.
• In an input matrix, this key will move the selection bar backward.
“Plus” Key

• In a selection list, this key will move the selection bar downward.
• In an input matrix, this key will move the selection bar forward.
“Enter” Key

E

• Opens the marked sub-menu or parameter.
• Confirms a changed parameter value.
“Escape” Key combination (press keys simultaneously)

+

• Closes a parameter without accepting the changes.
• Quits the current menu layer and returns to the next higher layer.

2. Turn power on the machine. Set EMPTY CAL, then FULL CAL, then do a mapping of the Empty Tank.
3. Set EMPTY CAL to .939 meters:
a. Press E, then +, +, to get to Set Up. Then press E to get to EMPTY CAL, then press E.
b. Press + until decimal point (.) appears, then press E.
c.

Press + until 9 appears, then press E.

d. Press + until 3 appears, then press E.
e. Press + until 9 appears, then press E.
f.

Press and hold E until the hourglass appears, then release.

3A2989G

25

Repair

4. Set FULL CAL to .691 meters.
a. Press + to get to FULL CAL, then press E.
b. Press + until decimal point (.) appears, then press E.
c.

Press + until 6 appears, then press E.

d. Press + until 9 appears, then press E.
e. Press + until 1 appears, then press E.
f.

Press and hold E until the hourglass appears, then release.

5. Map EMPTY TANK.
a. Press + to get to MAPPING, then press E.
b. Press E to get to CONFIRM DISTANCE.
c.

Press + until TANK EMPTY appears, then press E.

d. Press + under the check mark to confirm, END OF SEQUENCE will appear. Press and hold E until the hourglass appears, then release.
e. You are now finished. Press + and - together until the hourglass appears, then release.
6. The transmitter display should show nothing in the tank. Check the level display on the PFP machine control. It
should also show the tank as empty.
7. These settings can now be locked from display control so they will not be inadvertently changed.
8. Set display to lock ON:
a. Turn display counter-clockwise to release it as shown below (2).
b. Set the dip switch to the lock position as shown below (3).
c.

Replace display (4).

d. Replace screw on lid (5).
e. Engage cover securing clamp.

26

3A2989G

Electrical Schematics

Electrical Schematics
Simplified Electrical Schematic
Page 1 of 3
DISC1
Switch - 123969
thpole - 123968
4

24VDC
POWER

16T147
Din rail
PS1

L3

RED +V
BLACK -V

L2

GND-3

L1

+
+
24VDC
- Power Supply
-

CB5-3 3
CB5-1 1

N

CB4-3 3
FIELD
WIRE
SIDE

GRACO
WIRE
SIDE

CB4-1 1
CB3-3 3
CB3-1 1
CB2-3 3
CB2-1 1
CB1-3
CB1-1

3
1

CB5
30A
126130
CB4
20A
126128
CB3
30A
126130
CB2
20A
126128
CB1
25A
126129

L

L

N

N
GND

GND-2

4

CB5-4

TCMA-5L2

2

CB5-2

TCMA-5L1

4

CB4-4

TCMH-5L2

2

CB4-2

TCMH5L1

4

CB3-4

TCMB-5L2

2

CB3-2

TCMB-5L1

4

CB2-4

2

CB2-2

4

CB1-4

SW3-3
SW1-3
SW3-1
SW1-1
SW2-3

CB1-2

SW2-1

2

TB8-2
TB8-1

TB8

TB8-2
TB7-2

TB7

TB6

KEY:

TB7-2
TB6-2
TB5-2

230VAC
DELTA
JUMPER
POSITIONS

TB5-1

TB5

TB5-2
TB4-2

TB4

TB4-2
TB3-2

TB3-1
TB3

380VAC
WYE
JUMPER
POSITIONS

TB2-2
TB2

TB2-2
TB1-2

TB1-1
TB1

3A2989G

TB1-2

27

28
SW3 -4

WH ITE

GND-2

NEMA
L6-20P

NEMA
L6-30P

NEMA
L6-20P
3

1

3

SW2-1

SW3 -3

SW3 -1

SW2-3

GND-2
TCMH
255774

2
3

GND-2
TCMA-3L1

26
6

TCMA-3L2

TCMH-6
6
TCMB-6

WHITE

TCMA-5L2
GND-2
TCMA-5L1

BLACK

TCMA-5L1

126511

3

TCMH-3L1

2
Cable
125789

TCMH-3L2

TCMB
255774

WHITE

6

BLACK

6

125357

SW2-1

TCMB -3L2

SW3-3
SW1-3
SW3-1
SW1-1
SW2-3

WHITE

5

TCMB -3L1

TCMB-5L2
GND-2
TCMB-5L1

BLACK

126511

SW3
Switch -15U423

1

TCMB-5L1

4

2

4

2

TCMA-5L2

A FLU ID HEATER
5.4KW
262853

SW3 -2

SW2 -4

WH ITE

SW2
Switch - 15U423

SW1 -3

TCMH5L1
TCMH-5L2
GND-2
TCMH-5L1

126427

GND-2
BLACK

SW2 -2

3

SW1 -1

TCMH-5L2

HOSE HEATER
4KW
245869

Power
Distribution
Enclosure
BLACK

4

1

TCMB-5L2

Splitter
125806

NEMA
L6-20R

A TANK HEATER
1.75KW
16T525

24P242

NEMA
L6-30R

FLUSH HEATER
5KW
16T859

SW1 -4

WH ITE

2

SW1
Switch -15U423

TCMB-6

GND-2

B FLU ID HEATER
5.4KW
262853

NEMA
L6-20R

B TANK HEATER
1.75KW
16T525

SW1 -2

24VDC
POWER

BLACK

Electrical Schematics

Page 2 of 3

16T147

5

5
TCMA-6
6 TCMA 6
CAN
TCMH-6
TCMA-6
255774
Cable
125789

2
3

GND-2
GND-2

1 2

3A2989G

Electrical Schematics

Page 3 of 3

5
FCM1
7
Base - 289697
FCM - 289696
1 121806
126495

2 121806

126496

126494

16T072

DISPLAY SHIELD
15M483
DISPLAY
FRONT 255727

3

1
AFCM
255920

2

15M976

4

5

5

3A2989G

Dose B
Motor B

15U542

121683
B Tank RTD
126381

121683

Reed Switch

Manifold
256555

15M977

3

15U542 4

A Tank RTD
126381

Linear Sensor - 256893

USB

Stop - 121619

15M669

Air Motor Junction Box
NXT411

15M974

15M669

15M975
1
15M977 2

127172

B
GREEN

A LEVEL SENSOR
24T052

15R324

15V778

A BLUE
Start - 121618
Manifold
256555

15V779

127172

DISPLAY LCD
288997
USB1
Base - 289899
USB - 289900

Dose A
Motor A

SETUP
KEY 121617

B LEVEL SENSOR
24T052

16T123

Manifold

Control Enclosure

Buzzer - 122000

126494

Soleno id A

Power
Distribution
Enclosure

Soleno id B

CAN

FCM1

FCM1

124273

Air Motor Junction Box
NXT411
Linear Sensor - 256893
Reed Switch

29

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Electrical Schematics

XM PFP Air Logic Schematic

3A2989G

3A2989G

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5HOLHI

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Electrical Schematics

Feed Module Air Controls Schematic

31

Parts

Parts
XM PFP System (262869, 24W626)
Ref. Part
1
262878
24W648
2
24P202
24W628
2a 24P883
2b* C20461
2c‡ 100505
2d‡ 156849
2f◆ 15U654

Description
Qty.
SYSTEM MODULE AND MIX LINE
1
Model 262869
Model 24W626
FEED MODULES ASSEMBLY
1
Model 262869
Model 24W626
FEED MODULE
2
NIPPLE, reducing
1
BUSHING
1
NIPPLE
1
LABEL, A/B Identification
1

Ref. Part
2g◆ 061134
2h◆ --3
16T121
16T122

Description
HOSE, nylon
CABLE TIE
HEATED HOSE BUNDLE
Model 262869
Model 24W626

Qty.
2.5
8
1

--- Not for sale.
◆ Not shown.
‡ Not required for model 24W626.
* Qty. 2 required for 24W626.

1

‡2c

3

‡2d

2a

1

2a

*2b
ti20491a

32

3A2989G

Parts

XM PFP System (262869, 24W626) Subassemblies
Base System (262878, 24W648)
Page 1 of 5
46

85
95

96

61

97

99

98
61

ti20154a

Heated Hose Bundle 16T121. Not included with assemblies 262878 and 262869.
Shown for reference only.
Heated Hose Bundle 16T122 not included with assembly 24W648 and 24W626.
Shown for reference only.
NOTE: Apply pipe sealant to all non-swiveling pipe threads.

3A2989G

33

Parts

Base System (262878, 24W648) page 2 of 5
Set air regulator to 85 psi
(590 kPa, 5.9 bar)

102
103

140a

101

30

104
32

140
67
10

45, 11

61
33
35
38

67

39

43

61

144
143
145
146
147
148

11

36
44

140

54
2

67
4, 5

152

153

8

7 6
9

57

60
149
150

151

43
1
94
41

154

44 54

3
ti20156a

36

155

34

3A2989G

Parts

Base System (262878, 24W648) page 3 of 5

29

28
56
27

37

85
36

55
31

54

67
60

118 105
67 59

120

ti20157a

3A2989G

35

Parts

Base System (262878, 24W648) page 4 of 5

133

110

109

132

17

86
16

15

19

112

116

111

115

52

117

40

108
114
9
113
23

114

25
26

21
20

17

36

22

24

ti20158b

18

3A2989G

Parts

Base System (262878, 24W648) page 5 of 5
78

79

127

120

12
9
54

132
107

133
87

15

106

64
13

93

100

34
82
100

85
ti20159b

54
12

3A2989G

37

Parts

Base System (262878, 24W648)
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

37

38
39
40
41
42

38

Part
Description
Qty
--FRAME
1
L180C9 PUMP; B side lower
1
L220C9 PUMP; A side lower
1
100133 WASHER, lock, 3/8
8
100101 SCREW, cap, hex head
8
256169 PLATE, solvent pump
1
121488 SCREW, hex head, flanged
2
W30CAS PUMP, solvent, 6.0 in, 75 cc; see
1
312794
112395 SCREW, cap, flange head
8
24N598 JUNCTION BOX; see page 45
1
113796 SCREW, flanged, hex head
6
262853 HEATER, Viscon HF
2
245869 HEATER, Viscon HP
1
24P899 FILTER, air, 1-1/4, assembly
1
126899 FITTING, compression, straight
2
255771 BOX, control, air/electric
1
112958 NUT, hex, flanged
10
255761 MODULE, air controls, upper
1
--COVER, shroud, rear
1
256177 COVER, shroud, front
1
117623 NUT, cap, 3/8-16
4
--LABEL, XM PFP
1
15T567 NUT, backup plate, hinge
4
15T568 DOOR, control shroud
1
121471 HINGE, friction, positioning
2
112380 SCREW, mach, pan head
8
113498 VALVE, safety, 110 psi
1
--VALVE, ratio control, left; see
1
page 50
--VALVE, ratio control, right; see
1
page 50
C19024 FITTING, elbow, swivel
1
111801 SCREW, cap, hex head
8
217430 FITTING, swivel, union, 90 degree
1
15T536 REGULATOR, air, 3/8 npt
1
100329 BUSHING, pipe
1
116504 FITTING, tee, run
1
C20461 FITTING, nipple, reducing, hex
Model 262878
3
Model 24W648
2
160032 FITTING, nipple
Model 262878
2
Model 24W648
4
116643 VALVE, safety, relief, air
1
101689 GAUGE, press, air
1
121688 CONNECTOR, 3/8 npti x 3/8 tube
1
ptc
115313 PLUG, tube
8
160327 FITTING, union adapter, 90
2
degree

Ref
43
44
45
46

Part
15J277
15M987
117666
262893

47
48
49
50
52
53▲

------206995
108636
15X393

54

H75003

55

H75004

56

H73806

57

H42506

58
59
60
61◆
62
63
64

205418
16P244
248208
159239
16A004
121456
125806

65

126511

66

16T123

67
68
69

240900
054172
054175

70
71
73
74

551390
--238909
C12508

76
79

109025
16P856

80

125357

81
82

126494
126351

Description
Qty
CONTROL, de-ice, assembly
2
FITTING, elbow, 60 degree
2
TERMINAL, ground
1
MANIFOLD, mix; see manual
1
3A2988
SEALANT, pipe, stainless steel
1
LUBRICANT, thread
1
SEALANT, anaerobic
1
FLUID, TSL, 1 qt.
1
MUFFLER
1
LABEL, warning, USB, all
1
languages
HOSE, coupled, 7250 psi,
3
0.50 in. ID, 3 ft
HOSE, coupled, 7250 psi,
0.50 in. ID, 4 ft
Model 262878
3
Model 24W648
5
1
HOSE, coupled, 7250 psi,
0.375 in. ID, 6 ft
(Model 262878 only)
HOSE, coupled, 4500 psi,
1
0.25 in. ID, 6 ft
HOSE, coupled, air, 1/2 x 6 ft
2
HOSE, coupled, air, 5/16 x 3 ft
2
HOSE, coupled, air, 5/16 x 4 ft
1
FITTING, nipple, pipe, reducing
4
FLASH DRIVE, USB, 2.0
1
CONNECTOR, power, male, 3 pin
1
CABLE, splitter, M8, 4-pin,
1
female/female/male, 1.5 m
CABLE, GCA, M8, 4-pin, 1.5 m,
2
male/female
CABLE, GCA, CAN, male/female,
1
1.0 m
HOSE, coupled, air, 30 in. x 3/4 in.
3
TUBE, nylon, round, black, 1/4 in. 26.5
TUBE, nylon, round, natural,
8.5
1/4 in.
SIGHTGLASS, beaker, graduated 10
STRAP, tie
20
WIRE, grounding assembly
1
TUBING, nylon, round, black,
4.7
3/8 in.
TERMINAL, ring
1
LABEL, codes, alerts; all
1
languages
CABLE, M8, 4-pin, male/female,
1
1 meter
CABLE, M12, 5p, 4-wire with drain
2
FITTING, compression,
1
thermocouple
3A2989G

Parts

Ref Part
Description
Qty
85◆ H75002 HOSE, coupled, 7250 psi, 0.5 in.
2
(12 mm) ID, 2 ft
86
--TUBE, 0.375 in. (9.5mm) ID blue
6
nylon
87
--TUBE, 0.375 in. (12 mm) ID red
1.5
nylon
88
114601 CONDUIT, flexible, non-metallic
3.5
92
15T258 TOOL, wrench, Xtreme, 145/290
1
93
24P242 SENSOR, RTD, 1k ohm, insulated
1
94
158586 FITTING, bushing
1
95◆ 16T316 MIXER, static, assembly
1
96◆ H75010 HOSE, coupled, 7250 psi, 0.50 ID,
1
10 ft
97◆ H73803 HOSE, coupled, 7250 psi, 0.375
1
ID, 3 ft
98◆ 24P834 SWIVEL, straight
1
99◆ 262854 GUN, spray
1
100 126427 SENSOR, RTD, 1K ohm, 4 pin,
1
8 in.
101 158990 MANIFOLD, air
1
102 165198 FITTING, nipple, reducing
1
103 121858 FITTING, elbow, 3/8 npte x 1/4
1
npte
104 101754 PLUG, pipe
1
105 119798 CONNECTOR, tee, push-tube
1
106 126896 FITTING, elbow, tube
1
107 121603 GRIP, cord, 0.51-0.71, 3/4
1
108 16T745 BRACKET, water circulation,
1
mount
109 16R871 BOTTLE, overflow, 1/2npt
1
110 113161 SCREW, flange, hex head
2
111 108126 FITTING, tee, street
1
112 126898 FITTING, elbow
1
113 D11021 PUMP, diaphragm
1
114 126897 FITTING, elbow
2
115 206264 VALVE, needle
1
116 151519 FITTING, nipple, reducing
1
117 15R472 FASTENER, hex head, flanged,
4
1/4 x 1
118 054760 TUBE, polyurethane, round, black
5
119 100028 WASHER, lock
1
120 115901 TRIM, edge, protection
2
121 16T171 STRAP, frame connector
2
122 100679 SCREW, cap, hex head
8
123 115211 SCREW, cap, hex head
2
124 --SCREW, hex head with serrated
8
face flange base, 1/2-13
125 109570 WASHER, plain
20
126 112731 NUT, hex, flanged
10
127▲ 15W598 LABEL, warning
1
128 15U654 LABEL, identification, A/B
1
129 --FLUID, ethylene glycol/water
2

3A2989G

Ref
131

Part
Description
Qty
16F366 FITTING, 1/4 in. x 1/4 in. push to
2
connect
132 126346 FITTING, tee, tube x tube x nptm
2
133 126345 FITTING, elbow, tube x nptf
2
135 121683 CABLE, M8, 4-pin, male/female,
2
3 meter
136 122032 NUT, wire
2
137 15V778 CABLE, CAN, female-female,
1
20 in.
138 15V779 CABLE, CAN, female-female,
1
34 in.
140 257055 MOTOR, 6500 with sensor
2
140a 256893 LINEAR SENSOR ASSEMBLY
141 100133 WASHER, lock
8
142 100101 SCREW
8
143 257150 ROD, tie
6
144 197340 COVER, coupler
2
145 15H392 ROD, adapter
2
146 244820 CLIP, hairpin lanyard
2
147 244819 COUPLING, assembly rod
2
148 101712 NUT, nyloc
6
149 157350 ADAPTER, 3/8 x 1/4
1
150 100081 BUSHING
1
151 116395 UNION, 90 degree, 1/4 male x 3/8
1
swivel
152 256561 PLATE, mount, pump
1
153 111799 SCREW, M8 x 1.25 x 16 mm
4
154 256421 HOSE, siphon
1
155 181073 STRAINER, inlet
1
--- Not for sale.
▲ Replacement Danger and Warning labels, tags and
cards are available at no cost.
◆ Included in mix line and gun kit 24P833.

39

Parts

Feed Module (24P883)
Page 1 of 2
298
217

246
243

297

213
219

212
201

213

219
273

211

218

267

209

215
266
265
268, 215

219a

272
208
202

207

300
247
210
216

269
254

230
270

213 211

253
233

206
254

271
252

251
252

220

40

222

WLF

Turns clockwise
as viewed from
the top

3A2989G

Parts

Page 2 of 2

259
260
261
223

227

258
257
231
262

224

225

227a
224
250

213

249
250

227c

226
229
277

228
224
276
227b

ti20161c

3A2989G

41

Parts

Feed Module (24P883)
Ref
201
202
203

Part
--24M683
---

204
205

111841
---

206
207

16R869
---

208

126351

209

126381

210
211
212
213
215
216

126898
295847
16T481
157785
171988
16T619

217

24P885

218

---

219
220
221
222
223
224
225
226
227◆

24T052
D11021
100016
102040
262860
113796
16R871
16T525
262868

227a P40DCS
227b
227c
228
229
230
231
232
233
234

257620
257727
GC2041
100017
117426
104633
--103475
---

235

---

236
237
238
239
240
241
242
243
246

205418
109130
16P244
15B772
054172
054753
--115313
215241

247

16T244

42

Description
FRAME
TANK, pressure, assembly
BOLT, hex head, 3.25 in. long,
5/8-11
WASHER, plain 5/8
NUT, self-locking hex, nylon
insert, 5/8-11
COVER, tank wrap
BUSHING, pipe, hex head,
3/4 npt x 1/8 npt, steel
FITTING, compression, thermocouple
SENSOR, RTD, 1k ohm, 4 pin,
3 in.
FITTING, elbow
FITTING, elbow, 90, 3/4 mpt
VALVE, check (see page 57)
FITTING, swivel
GASKET, inspection cap
FITTING, nipple, thread on one
end
AGITATOR, assembly, air (see
page 51)
MANIFOLD, assembly, air (see
page 53)
SENSOR ASSEMBLY, level
PUMP, diaphragm
WASHER, lock
NUT, lock, hex
PANEL, assembly, air
SCREW, flanged, hex head
BOTTLE, overflow, 1/2 npt
HEATER, fluid, 240V, Viscon LT
SUPPLY UNIT, 40:1, 0 volt, S20,
20L
PUMP AND MOTOR, see manual 312376
S20 RAM, see 313527
PLATEN, pail, see 313527
WASHER, flat, std, 1/2
SCREW, cap, hex head
INSERT, tube
VALVE, pilot
SEALANT, pipe, stainless steel
FITTING, tee, pipe
TUBE, 0.375 in. (9.5mm) ID red
nylon
TUBE, 0.375 in. (9.5mm) ID blue
nylon
HOSE, coupled
HOSE, coupled, 48 in.
HOSE, coupled, 3 feet
HOSE, air, 18 inch
TUBE, nylon, round
TUBE, nylon, round, black
TUBE, 0.275 in. ID black nylon
PLUG, tube
HOSE, 3/4 in. x 6 ft, 6000 psi
(41 MPa, 410 bar)
VALVE, pressure relief, 3/4 in.
female npt

Qty
1
1
4
8
4
1
1
1
1
2
2
1
4
1
1
1
1
1
1
4
4
1
8
1
1
1
1
1
1
4
4
6
1
1
1
3.8
4.2

Ref
248
249
250
251
252
253
254
255
257
258
259
260
261
262
263
264
265
266

Part
--108126
126899
112782
126897
115764
190451
--116395
103656
198171
593538
112781
24K976
100505
155665
16R985
16R983

267
268
269

24P837
210575
16T245

270
271
272
273
274
275
276
277
296
297
298★
299
300

16T396
257604
102726
109212
115219
262820
126900
126692
156172
260067
127172
102726
117571

Description
TIE, cable, 14 in.
FITTING, tee, street
FITTING, compression, straight
ELBOW, swivel, 90 degree
FITTING, elbow
FITTING, elbow, 90 degree
UNION, adapter
LABEL, part description
FITTING, swivel, elbow
FITTING, pipe, hex
FITTING, elbow
VALVE, shuttle 1/8 nptf
ELBOW, swivel, 90 degree
MUFFLER, 1/4 npt
BUSHING, pipe
UNION, adapter
FITTING, nipple, 2 npt
FITTING, adapter, 2 npt to
3/4 npt
GASKET, agitator
CAP, filler
COUPLING, shaft, one piece
clamp
SHAFT, agitator, lower
BLADE ASSEMBLY
PLUG, pipe headless
SCREW, socket cap head
FITTING, tee, 1/4 npt
KIT, fluid outlet, flexible
CONNECTOR, male
CONNECTOR, male
FITTING, union, swivel
FITTING, strain relief
CABLE, M12, 5-pin, 4-wire
PLUG, pipe, headless
GASKET, santoprene

Qty
20
1
2
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1

--- Not for sale.
◆ See Supply Systems manuals 313526 and 313527
for detailed instructions and parts list for the S20
Supply Unit (262868).
★ Included in radar level sensor kit 24T052. See
Replace Radar Level Sensor on page 24.
NOTE: 24T052 Level sensor with the blue head
replaces the 24P884 sensor with the red head.
24T052 includes #298

1
1
3
3
12
8
5.5
6
1
1

3A2989G

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

Parts

Heated Hose Bundle
16T121 - 3/4 in. x 1/2 in. (included in model 262869)
16T122 - 3/4 in. x 3/4 in. (included in model 24W626)

305 (blue)

308

305

310b

310c

304

302 (red)
303
309
307

301

303
302
310a
306

ti20243a

Ref
301

Part
Description
Qty
H67550 HOSE, coupled, 3/4 in., 6500 psi;
Model 16T121 - Qty 1
Model 16T122 - Qty 2
302
16X027 KIT, tube, 0.375 (9.5mm) ID red
2
nylon
303
H42550 HOSE, coupled, 4500 psi, 1/4 in. ID, 1
50 ft (15.2 m)
304
--LABEL, identification
1
305
16X028 KIT, tube, 0.375 in. (9.5mm) ID blue
2
nylon
306
--TAPE, electrical
1
307
--TUBE, insulation, 2-5/8 in. ID, 50 ft
1
(15.2 m)
308
H75050 HOSE, coupled, 7250 psi, 1/2 in. ID, 1
50 ft (15.2 m); Model 16T121 only
309
16T138 JACKET, scuff, 50 ft (15.2 m)
1
310
16U666 KIT, tube fittings
1
310a 126894 UNION, 1/2 in. tube x 1/2 in. tube
4
310b 126898 ELBOW, 1/2 in. tube x 1/2 nptm
2
3A2989G

Ref
Part
310c 126896
311◆ 16U111
311a◆ C20487
311b◆ 158491
311c◆ 156823
311d◆ 156971

Description
ELBOW, 1/2 in. tube x 1/2 nptf
KIT, fittings, hose connection
NIPPLE, hex
NIPPLE
UNION, swivel
NIPPLE, short

Qty
2
1
2
1
2
1

--- Not for sale.
◆ Not shown.

43

Parts

Base System (262878, 24W648) Subassemblies
System Air Controls Module (255761)
NOTE: For Feed Module Air Panel (262860) parts, see page 55.
616

617

644

607

608
613
610

603

611
609

Ref. 27

615

645
642

626
619

637

636

638

632

629

612

632

613

635
617
646

643
618
628

630
627
640 631
Ref.
603
604
606
607
608
609*
610
611
612
613
615
616
617
618
619
620
621
622
625
626
627
628
629
630
631

44

606

625

Part
157350
108307
101689
117346
114316
114109
158962
116643
100721
119992
156589
113911
160327
15T119
--15R437
121432
115942
116513
121457
121424
100451
114151
100264
116514

627

635

629
634
633

642
621

622

633

647

604
641

620

618

Description
Qty.
NIPPLE, pipe; 1/2 x 3/8 npt
1
ELBOW, pipe, male
1
GAUGE, press, air
2
VALVE, ball, vented
1
ELBOW, male, swivel
1
ELBOW, male, swivel; 1/4 OD tube
2
ELBOW, street; 1/4(f) x 1/8(m)
1
VALVE, safety, relief, air
1
PLUG, pipe
3
PIPE, nipple; 3/4 x 3/4 npt
2
ADAPTER, union; 90 deg.
1
GAUGE, pressure, air
1
ADAPTER, union; 90 deg.
2
LABEL, control
1
BRACKET, air controls
1
BRACKET, adapter, air controls
2
SCREW, machine, hex flat head
2
NUT, hex, flange head
4
REGULATOR, air
1
VALVE, ball, air, panel mounted
1
GAUGE, pressure, panel mount, 1.5 in.
1
COUPLING
1
ELBOW, male, swivel
2
SCREW, machine, pan head
2
NUT, regulator
1

Ref.
632

Part
054760

633
634
635
636
637
638
640★
641★
642★
643★
644★
644a
645★
646★
647★

--100840
162453
114114
114128
164259
122336
113440
113431
113442
15R488
123454
15R487
15R486
15R485

Description
Qty.
TUBE, polyurethane, round, black; 1.25
in.
TUBE, polyurethane, round; 0.6 ft.
ELBOW, street
1
FITTING; 1/4 npsm x 1/4 npt
2
ELBOW, male, swivel
1
ELBOW, male, swivel
1
ELBOW, street
1
NUT, panel, regulator
1
ADAPTER
2
CLAMP, quick
4
BLOCK, porting
2
REGULATOR
1
FILTER, element; 5 micron
1
REGULATOR
1
MUFFLER
1
VALVE, dual pilot
1

★ Parts included in Air Controls Kit 255772 (purchase separately).
--- Not for sale.

3A2989G

Parts

Junction Box (24N598)

403, 446
412

402

403

418, 419, 423

411

4

413, 414, 443

404

415, 445

416

442
B

HOSE

A

422,
439
417,
444
405
405a
ti20155a

407, 408

405b

405f

405c 405e 406 403 407

420 421

425 442

426, 427

409
410
401

4

Set High Power Temperature Control Module zone addresses on dial
under cover when installing modules (404). Addresses: B Module =1,
Hose Module = 2, A Module = 0.
NOTE: See Electrical Schematics beginning on page 27 for cable
identification.

3A2989G

45

Parts

Junction Box (24N598)
Ref
401
402
403
404◆
405
405a
405b
405c
405d
405e
405f
406
407

Part
----114231
255774
--126382
126129
126130
126684
126453
126128
121603
255047

408 255048
409 15U423
410 123967
411 123968
412 123969
413† 289697
414 104371
415z† 289696
416 117666
417 115942
418 15U651
419 117831
420 --421 109466
422 104387
423 113161
425 126496
426
426a
426b
426c
427
428

--121636
15A798
15A799
106084
125789

429

123422

430

121615

432
433
434
435
436
437
438

126495
124273
--126494
121806
--16T147

439

16P626

46

Description
Qty
ENCLOSURE
1
BRACKET, module
3
NUT, lock, hex
16
MODULE, GCA, HPTCM
3
MODULE, breaker
1
BLOCK, terminal
8
BREAKER, 25A
1
BREAKER, 30A
2
JUMPER, red
3
POWER SUPPLY, 24V
1
BREAKER, 20A
2
GRIP, cord, 0.51-0.71, 3/4
6
BUSHING, strain relief, M40
2
thread
NUT, strain relief, M40 thread
2
SWITCH, 2p, 25a
3
KNOB, operator disconnect
1
SWITCH, disconnect, 100 amp
1
SWITCH, disconnect, 100 amp
1
MODULE, GCA, cube, base
1
SCREW, cap sch 10 x 0.375
4
MODULE, GCA, cube, FCM
1
TERMINAL, ground
1
NUT, hex, flange head
1
BRACKET, high power, GCA
6
SCREW, machine, pan head
12
BAR, ground
1
NUT, lock, hex
2
SCREW, machine, pan head
4
SCREW, flange, hex head
6
CONNECTOR, thru, M12, male x
1
female, reverse key
MODULE, solenoid
1
VALVE, solenoid
2
GASKET, outlet
1
GASKET, inlet
1
SCREW, machine, pan head
2
CABLE, CAN, female / female,
2
0.5 m
CABLE, CAN, 5-pin, female /
2
female, 0.4 m
HARNESS, splitter, M8, 4-pin,
1
female/female/male, 3 m
CABLE, splitter, 4-20ma, 2 circuit
1
CONNECTOR, splitter
1
STRAP, tie
14
CABLE, M12, 5p, 4wire with drain
2
CABLE, solenoid
2
STRIP, foam, neoprene
10
CABLE, can power, M12 female,
1
pigtail
LATCH, enclosure
4

Ref Part
Description
Qty
1
440▲ 16T278 LABEL, multi-purpose; including
warnings text, shock arrow,
ground symbol, and various informational stickers
442 16T072 ADAPTER, cable, CAN
1
443 126687 SCREW, machine, pan head
1
444 558685 WASHER, lock, external type, 1/4
1
445† 277674 ENCLOSURE, cube door
1
446 555629 WASHER, lock, external type, #10
2

--- Not for sale.
▲ Replacement Danger and Warning labels, tags and
cards are available at no cost.
z Base electronic components do not have
XM PFP-specific software installed. Therefore, use
software upgrade token (506) to install software
before use.
† Parts available in Fluid Control Module Cube Kit
24R902. Kit includes items 413, 415, 445, software
token (506), and instructions.
◆ Parts available in High Power Temperature Control
Module Kit 24R903. Kit includes items 404, software
token (506), and instructions.

3A2989G

Parts

Control Box (255771)
543

532 538

539

504b

504f

501

504h
504e

551
536

502
523

521

504g
532

504c

538
537

504a, 504d

545

540

508

541
520

522
535

543

502

526

526
544

530

527
507

542
503

501 543

529

509

528

514

515

510

517

542
533

534

526

524, 525
546

519c
ti18050a

Ref.
501
502
503†

Part
----24R899

504z 257484
504a 15M483
504b --z504c 288997
504d 255727
504e 277463
504f 113768
504g 15R458
▲504h 15W958

3A2989G

Description
BOX, control
LABEL, control display
KIT, replacement, USB; includes
519 and 506
MODULE, display, kit
SHIELD, membrane, display (qty.
10)
SCREW, pan head; #6 x 7/8 in.
CASE, rear, display module, IS
version
CASE, front, data module
COVER, access, low level display
SCREW, socket, flat head
GASKET, control, front panel
LABEL, warning, battery

Qty
.
1
1
1
1
4
1
1
1
4
1
1

Ref.
505†

Part
Description
24R897 KIt, replacement, display; includes
504 and 506
506* 16P644 TOKEN, software
507† 24R898 KIT, replacement, FCM; includes
518 and 506
508
--SCREW, pan head
509
256555 MODULE, solenoid, IS version
509a 121636 VALVE, solenoid, din connector
509b 15A798 GASKET, solenoid, outlet
509c 15A799 GASKET, solenoid, inlet/exhaust
510
106084 SCREW, machine, pan head
514
15R379 GASKET, box, control
515
--LABEL
516❄ 15B056 LABEL, air motor/dosing valve
517
122000 ALARM, panel mount
518z 255920 MODULE, fluid control

Qty
.
1
1
1
4
1
4
1
1
2
1
1
1
1
1
47

Parts

Ref.
Part
519z 257088
519a 289899
z519b 289900
519c 277674
520
121618
521

15R324

522
121619
523
121617
523a❄ 123412
524
117745
525
117625
526
113505
527
15B090
528
--529
15R343
530
--531❄ 172953
532
120493
533
15H189
534
15G816
535
110637
536
15R325
537
538
539
540
541
542
543
544
545
546
551▲
552❄

120494
120495
15M974
15M975
15M976
15M977
121988
195875
102063
15U542
15X214
15X393
122829

Description
MODULE, USB, assy.
BASE
MODULE, USB
DOOR, module
SWITCH, start, push button,
green
HARNESS, USB, plug/bulkhead;
32 in.
SWITCH, stop, push button, red
SWITCH, 2 position, key, controls
KEY, replacement (pair)
BUSHING, strain relief
NUT, locking
NUT, keps, hex head
WIRE, grounding, door
WASHER, lock, external, 1/4 in.
CLAMP, ground, electrical
WIRE, copper
LABEL, designation
LATCH, mounting
BOOT, wire feed through
COVER, plate, wire
SCREW, machine, pan head
COVER, dust, bulkhead
receptacle
BLOCK, switch, normally open
BLOCK, switch, normally closed
HARNESS, key switch
HARNESS, start/alarm
HARNESS, stop
HARNESS, solenoid
RETAINER, routing, wire harness
SCREW, machine, pan head
WASHER, lock
CABLE, motor
LABEL, warning, USB
English
All languages
CONDUIT; 0.75 ft.

Qty
.
1
1
1
1
1
1
1
1
1
6
1
1
1
3
2
3
1
1
4
1
2
1
1
1
1
2
4
1
1
2
1
-

▲ Replacement Danger and Warning labels, tags, and
cards are available at no cost.
--- Not for sale.
❄ Not shown.
z Base electronic components do not have
XM PFP-specific software installed. Therefore, use
software upgrade token (506) to install software
before use.
† Includes software token (506) and instruction sheet.

48

3A2989G

Parts

Air Filter (24P899)

706
707

711
705

711
704

702

703

701
702
703

1

Apply PTFE tape and/or pipe sealant to all
non-swiveling pipe threads.

2

Orient fittings approximately as shown.

704
ti20218a

708

703
709

Ref
Part
701
16T236
701a◆ 106204
702
C19662
703
704
705
706
707
708
709
710
711

110300
158585
16R951
157785
C19024
113163
160022
--100361

Description
FILTER, air, 1-1/4, auto drain
FILTER ELEMENT
BUSHING, 1-1/4 x 1 npt carbon
steel
FITTING, elbow, street, pipe
FITTING, nipple
MANIFOLD, air distribution
FITTING, swivel
FITTING, elbow, swivel
VALVE, ball, vented, 1.00 in.
FITTING, union, adapter
SEALANT, pipe, stainless steel
PLUG, pipe

Qty
1
1
2
3
2
1
1
1
1
1
1
2

--- Not for sale.
◆ Not shown.

3A2989G

49

Parts

Ratio Control Valve Assemblies
1 852
1 854

1 836

801

1 852

836 1
837 1 8
15

1 855

840 1

1 853
839

857 1

14 831

8 832

858
8 833
851

Apply pipe sealant to all non-swiveling pipe threads.

8

Position valve (832) with barbed fitting (833) oriented as shown,
position elbow (837) as shown.
ti20219a

14

Torque until nut (831) bottoms out in housing.

15

Flip ball valve handle retainer (855). Handle to face forward in
open position.

Ref
801†
831
832
833
836
837
839
840

851
852
853

50

856

1

Part
255478
15M669
262872
116746
156684
15M987
121399
158491

Description
VALVE, dosing
SENSOR, pressure, fluid outlet
VALVE, pressure, bleed, PFP
FITTING, barbed, plated
FITTING, union, adapter
FITTING, elbow, 60 degree
PACKING, o-ring
FITTING, nipple
(B side only - Qty 1)
(A side only - Qty 2)
116750 TUBE, nylon
158683 FITTING, elbow, 90 degree
159239 FITTING, nipple, pipe, reducing
(B side only)

Qty
1
1
1
1
2
1
1

Ref
854
855
856
857
858

Part
156877
262739
16T481
502033
157785

Description
FITTING, nipple, long
VALVE, ball, 1/2 in.
VALVE, check; see page 57
FITTING, bushing, pipe
FITTING, swivel

Qty
1
1
1
1
1

† See Dosing Valve Instructions - Parts manual referenced on page 3 for further details.

1
2
1

3A2989G

Parts

Feed Module (24P883) Sub-Assemblies
Air Powered Agitator (24P885)

917 5
925

915

924
923

5 916
7 907
912
3 4 915
3 914
913

922

2
919
918
2 921

5 911
7 5 910
7 909
905

908 3
913

906

905
904
8 903
902

7 901

1

Apply pipe sealant to all non-swiveling pipe threads.

2

Apply low strength threadlocker.

3

Apply blue thread locker.

4

Remove four screws from gear reducer (915), pass them
through bracket (912) and back into gear reducer (915) then
torque to 150-170 in-lb (17-19 N•m).

3A2989G

5

Leave a 0.015 in. gap between each half of couplings (910,
911, 916, 917).

7

When ordering a replacement coupling: Remove set screw
supplied with couplings (910, 916) and discard. Replace with
set screw (931).

8

Open side of u-cup seal (903) must face down inside
housing (902).

51

Parts

Air Powered Agitator (24P885)
Ref
901
902
903

Part
16P919
16U219
---

904
905

--122774

906
907

16P920
---

908
909
910
911
912
913
914
915
916
917
918
919
920
921
922
923
924
925
926
927
928
929▲
930▲

112222
--122761
122760
16P922
C19209
101682
181794
16P923
100828
16T063
116940
181849
101118
111310
115841
206264
191872
------15A722
16A614

Description
Qty
SHAFT, agitator, upper
1
HOUSING, agitator
1
SEAL, 0.875 in. ID x 1.125 in. OD,
1
PTFE
SPACER, shaft, agitator, ASME
1
BEARING, ball, 3/4bore x 1-3/4 dia. x
2
1/2
HOUSING, bearing, agitator
1
SCREW, socket head set screw,
2
5/16-18 x 0.75
SCREW, socket cap head
4
RING, retaining, external, 0.750 in.
1
HOUSING, alignment, hub
1
COUPLING, alignment, disk, TPE
1
BRACKET, adapter, agitator
1
WASHER, lock
8
SCREW, socket cap head
4
GEAR, reducer
1
COUPLER, adapter
1
COUPLING, flexible
1
COLLAR, mounting
1
SCREW, cap, socket head, 5/16-18
2
COLLAR
1
SCREW
2
MOTOR, air, rotary
1
FITTING, elbow
1
VALVE, needle
1
FITTING, nipple, reducing
1
SEALANT, pipe, stainless steel
1
SEALANT, low strength thread locker
1
SEALANT, blue thread locker
1
TAG, warning, agitator
1
TAG, label, caution
1

--- Not for sale.
▲ Replacement Danger and Warning labels, tags and
cards are available at no cost.

52

3A2989G

Parts

Tank Air Manifold Assembly

1008
1010

1012
1011

1001
1004

1002

1013

1005

1003

1009
1008

1013

1003

Ref
1001
1002
1003
1004
1005
1006
1007
1008
1009
1010
1011
1012
1013
1014
1015

Part
189016
155665
156849
214847
165198
100840
103347
156971
108638
101759
101754
100139
100030
111856
---

1007

1006

1

Apply pipe sealant to all non-swiveling pipe threads.

2

Orient all fittings as shown.

Description
MANIFOLD, air, inlet
UNION, adapter
PIPE, nipple
LUBRICATOR, air line
FITTING, nipple, reducing
FITTING, elbow, street
VALVE, safety, 100 psi
FITTING, nipple, short
FITTING, pipe, tee
FITTING, drain cock
PLUG, pipe
PLUG, pipe
BUSHING
FITTING, elbow, street
SEALANT, pipe, stainless steel

Qty
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1

--- Not for sale.

3A2989G

53

Parts

Static Mixer (16T316)

1303
1301

1303

1302

1

Ref
1301
1302
1303

Part
--24P886
16T315

1304 ---

Apply pipe sealant to all non-swiveling pipe threads.

Description
Qty
TUBE, mixer
1
MIXER, 12 element, stainless steel
1
BUSHING, reducing 3/4 nptf x
2
1/2 npt
SEALANT, pipe, stainless steel
1

--- Not for sale.

54

3A2989G

Parts

Feed Module Air Panel (262860)
NOTE: For System Air Controls Module (255761) parts, see page 44.
1102
1103

1101

1123
1122

1103

1113
1114

1121

1104

1122
1128
1121

1109

1111
1120
1119
1118

1122
1116
1115
1117

1129

1130

1105
1106
1127
1125

1111
1113

1110

1114

1

3A2989G

Apply pipe sealant to all non-swiveling pipe threads.

55

Parts

Air Panel (262860)
Ref
1101
1102
1103

Part
----121424

1104

15T498

1105
1106

116513
121141

1109
1110
1111
1113
1114
1115
1116
1117
1118
1119

198171
100403
121457
155699
165198
104984
157705
156971
206264
114367

1120
1121
1122
1123
1124
1125

109544
110914
100264
116514
109193
16F151

1126
1127
1128
1129
1130

--054134
517305
106495
100840

Description
BRACKET, air control
LABEL, instructions
GAUGE, pressure, panel mount,
1.5 in.
FITTING, 90 degree, swivel,
5/32 in. tee x 1/8 in. female npt
REGULATOR, air
FITTING, elbow, swivel, 3/8 tee,
1/4 in. male npt
FITTING, elbow
PLUG, pipe
VALVE, ball, air, panel mounted
FITTING, elbow, street
FITTING, nipple, reducing
FITTING, tee, pipe
UNION, swivel
FITTING, nipple, short
VALVE, needle
FITTING, tube, qd, 90 degree
elbow
FITTING, elbow, pipe, male
VALVE, button, push
SCREW, mach, panhead
NUT, regulator mount
FITTING, tube, male, elbow
FITTING, elbow, swivel, 3/8 tee,
3/8 npt
SEALANT, pipe, stainless steel
TUBE, nylon, 3/8 in. OD
TUBE, nylon, 5/32 in. OD
VALVE, check, brass, 1/4 MBE
FITTING, elbow, street

Qty
1
1
1
1
1
1
1
1
2
3
3
1
1
1
1
1
1
1
4
1
2
1
1
1.1
0.7
1
1

--- Not for sale.

56

3A2989G

Parts

Check Valve (16T481)

Flexible Fluid Connection Kit (262820)
1412
1411
1401

1402
1404

1410

1205

1202

1407

1403
1404
1402
1405
1406

1206
1408

1207 1204 1203 1201 1
1
Ref
1201
1202
1203
1204
1205
1206
1207

1409

Torque to 75-80 ft-lb (102-108 N•m).

Part
--102595
100279
108361
--181492
181535

--- Not for sale.

3A2989G

Description
NUT, seat
PACKING, o-ring
BALL, metallic
SPRING, compression
HOUSING, ball check
GUIDE, ball
RETAINER, spring

Qty
1
1
1
1
1
3
1

Ref
1401
1402
1403
1404
1405
1406
1407
1408
1409
1410
1411
1412

Part
120291
125995
126320
126889
121440
121441
121443
101496
104663
121445
121436
121435

Description
PIPE, elbow female
FITTING, hose, barbed, 1-1/2 npt
HOSE, 1-1/2 ID, 200 psi, 3 ft
CLAMP, hose
VALVE, ball, 1-1/2 npt
FITTING, nipple, hex, 1-1/2 npt
FITTING, tee, 1-1/2npt
BUSHING, pipe
PLUG, pipe
SWIVEL, reducing, 1-1/2 x 1-1/4
FITTING, swivel, male, 2 in.
FITTING, nipple, hex, 2 in.

Qty
1
2
1
2
1
1
1
1
1
1
1
1

57

Technical Data

Technical Data
XM PFP
Mix Ratio Range
Ratio Tolerance Range (before alarm)
Maximum Flow Rate (measured with oil)
Fluid Viscosity Range

US
Metric
1:1-10:1 (in 0.01 increments)
+/- 5%
3 gallons per minute
13.6 liters per minute

Handles mastic materials which are loaded into heated tanks
with ram-fed priming piston pumps
Air Inlet
1 in. npt(f)
Fluid Inlets
Pail (Pail Feed RAM Pumps)
Maximum Fluid Working Pressure for A and B 6000 psi
41 MPa, 414 bar
Materials
Maximum Fluid Working Pressure for Flushing 4500 psi
31 MPa, 7 bar
Fluid
Maximum Fluid Working Pressure for Heating 100 psi
0.7 MPa, 7 bar
Fluid
Maximum Fluid Temperature
160°F
70°C
System Inlet Supplied Air Pressure Range
80-150 psi
0.5-1.0 MPa, 5.5-10.3 bar
Maximum Pump Air Pressure
100 psi
0.7 MPa, 7 bar
Maximum Tank Air Pressure
90 psi
0.6 MPa, 6 bar
Air Filtration
40 micron main filter, 5 micron control air filter
Ambient Operating Temperature Range
32 to 130°F
0 to 54°C
Ambient Storage Temperature Range
30 to 160°F
-1 to 71°C
Environmental Conditions Rating
Altitude up to 13,123 ft
Altitude up to 4000 m
Sound Pressure *
86 dBA at 100 psi
86 dBA at 0.7 MPa, 7 bar
Sound Power **
98 dBA at 100 psi
98 dBA at 0.7 MPa, 7 bar
System Weight (empty, no fluid)
2175 lb
987 kg
Air Consumption
Minimum
100 scfm
2.8 meter3/min
Maximum

250 scfm

7.1 meter3/min

Typical Application

125-175 scfm

3.5-5.0 meter3/min

Power Requirements
Voltage (can be set with jumpers)

Wattage
Amps

58

Option 1: 220-240V, 3 phase DELTA (3 wire plus ground)
Option 2: 380-400V, 3 phase WYE (4 wire including neutral
plus ground)
18,400 watts (23,400 with optional flush water heater)
240V, 3-phase models: 65 Amps per phase full load
380V, 3-phase models: 38 Amps per phase full load

3A2989G

Technical Data

XM PFP
US
Wetted Parts
Suction Tube (Flush)
Tanks
Flush Pump
Hoses
Pumps (A, B and Feed Pail)

Dosing Valves
Manifold

Metric

Aluminum
Stainless Steel
Carbide, PTFE, stainless steel, UHMWPE
Nylon
Carbon steel, alloy steel, 303, 440, 17-ph grades stainless
steel, zinc and nickel plating, ductile iron, tungsten carbide,
PTFE
Carbon Steel, nickel plating, carbide, polyethylene, leather
Carbon steel, nickel plating, carbide, 302 stainless steel,
PTFE, UHMWPE
Stainless steel housing with stainless elements

Mixer
Approvals
Machine
CE, ETL
Pressure Tanks
ASME, PED
Notes
* Sound pressure measured 3.3 feet (1 meter) from equipment.
** Sound power measured per ISO-9614-2.

3A2989G

59

Technical Data

Dimensions

Min: 70 in.
(1780 mm)
Max: 84 in.
(2130 mm)

76 in.
(1930 mm)

52 in.
(1320 mm)

Min: 70 in.
(1780 mm)
Max: 84 in.
(3130 mm)

104 in.
(2640 mm)
38 in.
(965 mm)
WLE

60

3A2989G

Notes

Notes

3A2989G

61

Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs
will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English. MM 3A2989

Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2012, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision G, January 2015



---

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Copyright                       : 2012, Revision G, January 2015
Marked                          : True
Web Statement                   : 3A2989G, XM PFP, Repair - Parts, (English) MM 3A2989
Keywords                        : "MM 3A2989, 3A2989G, 3A2989EN, 3A2989, 3A2989EN-G, XM PFP, Repair - Parts, English"..262869, 24W626
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Modify Date                     : 2015:02:12 16:38:59-06:00
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Metadata Date                   : 2015:02:12 16:38:59-06:00
Format                          : application/pdf
Creator                         : Emil Meindl
Description                     : 3A2989, XM PFP, Repair - Parts, English
Title                           : 3A2989G, XM PFP, Repair - Parts, (English)
Subject                         : MM 3A2989, 3A2989G, 3A2989EN, 3A2989, 3A2989EN-G, XM PFP, Repair - Parts, English, 262869, 24W626
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Page Count                      : 62
Author                          : Emil Meindl

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