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

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3A2989G

EN

Repair - Parts

XM PFP

For spraying two-component intumescent epoxies. For professional use only.

Not for use in explosive atmospheres or hazardous locations.

See page 3 for model information, including

maximum working pressure and approvals.

Important Safety Instructions

Read all warnings and instructions in all

supplied manuals. Save all instructions.

WLD

23A2989G

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

Models

3A2989G 3

Models

Related Manuals

Manuals are available at www.graco.com. Component

manuals in English:

Models

Maximum Fluid

Working Pressure

Maximum Air Working

Pressure Approvals

262869

24W626

A and B Materials:

6000 psi

(41 MPa, 414 bar)

Flushing Fluid:

4500 psi

(31 MPa, 310 bar)

Heating Fluid:

100 psi

(0.7 MPa, 7 bar)

Supply: 150 psi

(1.0 MPa, 10.3 bar)

Max. Setpoint: 100 psi

(0.7 MPa, 7 bar)

9902471

Certified to CAN/CSA C22.2 No. 88

Conforms to

UL 499

Manual Description

3A2776 XM PFP Setup - Operation

3A2988 XM PFP Mix Manifold Instructions - Parts

3A2799 XHF Spray Gun

Heaters

309524 Viscon

®

HP High Pressure Fluid Heater

Instructions - Parts

3A2954 Viscon HF High Flow, High Pressure Fluid

Heater Instructions - Parts

3A2824 Viscon LT Fluid Heater Instructions - Parts

Pumps, Motors, Supply Systems

308652 Husky

™

205 Air-Operated Diaphragm

Pumps Instructions - Parts

311238 NXT

®

Air Motor Instructions - Parts

311762 Xtreme

®

Lowers Instructions - Parts

312375 Check-Mate

®

Displacement Pumps

Instructions - Parts

312376 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

Accessories

332073 Hot Water Flush Kit Instructions

3A2987 Air Dryer Kit Instructions

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 Pro-

gramming

Manual Description

Warnings

43A2989G

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion 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.

WARNINGWARNINGWARNING

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.

Warnings

3A2989G 5

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 manu-

facturer’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.

WARNINGWARNINGWARNING

WARNING

Component Identification

63A2989G

Keep Components A and B

Separate

Changing Materials

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 com-

ponent flow. An integration hose must always be used

after the mix manifold and before the static mixer.

Component Identification

See XM PFP Operation manual for component identifi-

cation.

Grounding

Ground the electrical connection properly according to

local codes.

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 con-

taminated from the other side.

NOTICE

Changing the material types used in your equipment

requires special attention to avoid equipment damage

and downtime.

• When changing materials, flush the equipment mul-

tiple 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 compo-

nents and change hoses. Epoxies often have

amines on the B (hardener) side. Polyureas often

have amines on the B (resin) side.

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.

Pressure Relief Procedure

3A2989G 7

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

1. Engage trigger lock.

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 hard-

ening on the pump shaft.

3. Press (Stop button).

4. Slide the feed pump air supply valve (DF) and direc-

tor valve air supply valve (DA) to the OFF position.

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.

6. Open mix manifold ball valves.

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.

F

IG

. 1: Feed Pump Controls

TI19265a2

DF

DB

DA

DC

DD

DE

ti20104a

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 pre-

vent 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.

F

IG

. 2

FEED PUMP

BYPASS

ti20127a

ti20128a

Troubleshooting

83A2989G

7. Open recirculation ball valves.

8. Disengage trigger lock.

9. Hold a metal part of the gun firmly to a grounded

metal pail. Trigger gun to relieve pressure in mate-

rial hoses. Use a pail lid with a hole to dispense

through. Seal around hole and gun with a rag to pre-

vent splash back.

10. Engage trigger lock.

11. Close mix manifold material ball valves.

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.

14. If the system will be shutdown for more than a few

hours, fill pump A and B packing nuts with throat

seal liquid (TSL

™

).

NOTE: Fluid pressure in the system is now relieved.

Troubleshooting

See XM PFP Operation manual 3A2776 for trouble-

shooting details.

WLD

TI19265a1

TI1953a

TI19265a2

ti20129a

Repair

3A2989G 9

Repair

Follow Pressure Relief Procedure on page 7 if service

time may exceed pot life time, before servicing fluid

components, and before transporting sprayer.

Replace Air Filter Element

There are two air filters on the system: the inlet air regu-

lator filter on the air controls and the main air inlet mani-

fold filter. Check filters weekly and replace element as

needed.

Both Filters

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

on system. Depressurize air line.

Control Air Regulator Filter

2. Remove four nuts (21) and then remove front and

rear shrouds (19, 20).

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

4. Remove and replace element.

5. Screw filter bowl on securely.

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

nuts (21).

Main Air Inlet Manifold Filter

2. Unscrew filter bowl collar from main air inlet

filter (14).

3. Remove and replace filter element (701a). See Air

Filter (24P899), page 49.

4. Reassemble filter bowl.

NOTICE

Do not use air motor lift rings to lift the entire

assembly. This will damage the system. The sys-

tem must be lifted from the bottom.

To reduce the risk of serious injury, do not service air

filter until air line is depressurized. Removing a pres-

surized air filter bowl could cause serious injury.

21

20

19

ti19926a1

Filter Bowl

and Element

r_312359_313289_15

601d

14

ti199526a1

Repair

10 3A2989G

User Interface/Control Box

Remove Shroud and Front Panel of Control

Box

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

on system. Depressurize air line.

2. Remove four nuts (21) and then remove front and

rear shrouds (19, 20).

3. Disconnect power.

4. Remove four nuts (17); leave two nuts on left side of

panel tight. Open front panel of control box (16).

See F

IG

. 3.

Replace Single Solenoid Module

1. Remove Shroud and Front Panel of Control Box,

see page 10.

2. Disconnect solenoid cable connector (542) from the

solenoid (509a) being replaced.

3. Remove two screws (509b) from the solenoid being

replaced then remove solenoid (509a). See F

IG

. 4.

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

5. Reconnect solenoid cable connectors (542). See

Control Box (255771) on page 47.

NOTE:

From left to right, solenoid functions are as follows:

• Dosing valve A (DVA) (normally open)

• Dosing valve B (DVB) (normally open)

• Pump A (PA) (normally closed)

• Pump B (PA) (normally closed)

F

IG

. 3

21

20

19

ti19926a1

17

16

ti20158b1

F

IG

. 4

r_xm1a00_312359_313289_9_3

509b

509a

DVA

DVB

PA

PB

r_xm1a00_312359_313289_9_3

Repair

3A2989G 11

Update USB Module Software

1. Remove four nuts (21) and then remove front and

rear shrouds (19, 20).

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 soft-

ware versions may not be compatible.

All data in the module may be reset to factory

default settings. Record all settings and user prefer-

ences 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 USB Module

1. Remove Shroud and Front Panel of Control Box,

see page 10.

2. Disconnect CAN cables and USB cable from USB

module (519).

3. Remove two mounting screws from USB module

and remove module from base.

4. Follow steps in reverse order to install new USB

module.

5. Load software. See Update USB Module Soft-

ware.

21

20

19

ti19926a1

519

r_312359_313289_23a

Repair

12 3A2989G

Update Fluid Control Module (FCM)

Software

1. Remove four nuts (21) and then remove front and

rear shrouds (19, 20).

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 soft-

ware versions may not be compatible.

All data in the module may be reset to factory

default settings. Record all settings and user prefer-

ences 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 Fluid Control Module (FCM)

NOTE:

The USB module does not need to be removed prior to

replacing the FCM.

1. Remove Shroud and Front Panel of Control Box,

see page 10.

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

cable locations.

3. Loosen four mounting screws (535).

4. Slide FCM up and out of keyhole slots.

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

6. Load software. See Update Fluid Control Module

(FCM) Software.

7. Most of the system configuration is stored in the

FCM. Use the display to change the configuration to

the values in the old FCM. See XM PFP operation

manual for instructions.

Replace Alarm

1. Remove Shroud and Front Panel of Control Box,

see page 10.

2. Disconnect alarm wires from alarm (517).

3. Unscrew alarm (517) and replace.

4. Screw in new alarm. Reconnect alarm wires.

5. Reinstall front panel of control box and reinstall

shrouds.

21

20

19

ti19926a1

518

535

535

r_312359_313289_26

517

r_312359_313289_22

Repair

3A2989G 13

Display

Upgrade Software

Use software token 16P644. See Graco Control Archi-

tecture

™

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 soft-

ware versions may not be compatible.

All data in the module may be reset to factory

default settings. Record all settings and user prefer-

ences 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. Remove Shroud and Front Panel of Control Box,

see page 10.

2. Remove four screws (512) then remove access

cover (511).

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 soft-

ware is completely loaded.

6. Turn power off.

7. Remove token (T).

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

Replace Display Battery

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

on page 13.

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

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).

NOTICE

To avoid damaging circuit board, wear a grounding

strap.

L

T

512

511

Battery

r_xm1a00_312359_313289_2a

NOTICE

To avoid damaging circuit board, wear a grounding

strap.

Connector

Tabs

Remove Old Battery

Insert New Battery

r_xm1a00_312359_313289_9_8a

Repair

14 3A2989G

Replace Display

NOTE: Order display kit 257484 for replacement.

1. Remove Control Box Shrouds, see page 17.

2. Disconnect CAN cable from display module.

3. Remove four screws (505) from rear display panel

(506) while holding front display panel (507) in

place.

NOTE:

To ease removal use clear tape to hold front display

panel (507) in place.

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).

6. Discard old display assembly.

7. Place new front display panel (507) and

gasket (513) on front panel of control box (16).

NOTE:

To ease installation use clear tape to hold front display

panel in place.

8. Carefully connect display cables and key switch

cable to new circuit board.

9. Install new rear display panel (506) and secure with

four screws (505). Ensure key switch cable pro-

trudes from opening in top of display module.

10. Install access cover and screws. Apply warning

label to access cover.

11. Reconnect CAN cable to display module.

12. Reconnect power.

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

14. Replace shroud.

15. Configure system settings as they were set on old

display. See XM PFP Operation manual for instruc-

tions.

Replace Front Panel

See Replace Display, page 14, for instructions.

NOTICE

To avoid damaging circuit board, wear a grounding

strap.

r_312359_313289_24a

505

507

506

r_xm1a00_312359_313289_25a

505

506

513

507

Display Cable 539

Repair

3A2989G 15

Junction Box

Update High Power Temperature Control

Module (HPTCM, ref. 404) Software

NOTE: Upgrade all modules in the system to the

software version on the token, even if you are

replacing only one or two modules. Different soft-

ware versions may not be compatible.

All data in the module may be reset to factory

default settings. Record all settings and user prefer-

ences 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.

2. Use software token 16P644. See Graco Control

Architecture

™

Module Programming manual for

instructions.

Replace High Power Temperature Control

Module (HPTCM, ref. 404)

1. Turn system main power switch OFF.

2. Open junction box.

3. Unplug all connections on the HPTCM.

4. Remove screws securing HPTCM then remove

HPTCM.

5. Remove access door on new HPTCM. Set rotary

switches to the same number as the old module.

B module = 1. Hose module = 2. A module = 0.

6. Use screws to install HPTCM.

7. Reattach HPTCM connections.

8. Close junction box.

B HOSE A

404

ti20155a

ti21595a

ti12360a

Repair

16 3A2989G

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 soft-

ware versions may not be compatible.

All data in the module may be reset to factory

default settings. Record all settings and user prefer-

ences 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.

2. Use software token 16P644. See Graco Control

Architecture

™

Module Programming manual for

instructions.

Replace Fluid Control Module Cube (FCM3,

ref. 415)

1. Turn system main power switch OFF.

2. Open junction box.

3. Unplug all connections on the FCM3.

4. Remove two screws securing FCM3 then remove

FCM3.

5. Use screws to install FCM3.

6. Reattach FCM3 connections.

7. Perform Update Fluid Control Module Cube

(FCM3, ref. 415) Software on page 16.

8. Close junction box.

B HOSE A

415

ti20155a

ti21594a

Ground screw

Center ground screw in the Fluid Control Module

Cube must be used to avoid serious injury due to

electric shock.

Repair

3A2989G 17

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).

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.

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

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

See page 36.

4. Pull out assembly.

5. Remove two nuts (630) from front of air control

bracket (619). See F

IG

. 5 on page 18.

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.

8. Follow steps in reverse order to reassemble.

Replace Solvent Air Regulator

1. Remove Control Box Shrouds.

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

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

See page 36.

4. Pull out assembly.

5. Remove regulator nut (631), and disconnect air

lines (632, 633) running to regulator (625). See F

IG

.

5 on page 18.

6. Remove regulator assembly and replace with new.

See part number shown in the System Air Con-

trols Module (255761) section beginning on

page 44.

7. Follow steps in reverse order to reassemble.

Replace System Air Regulator

1. Remove Control Box Shrouds.

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

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

See page 36.

4. Pull out assembly.

5. Remove regulator nut (601h) and disconnect sys-

tem air line.

6. Remove screws from quick clamps and open

clamps (601f) at hinge.

7. Remove regulator assembly (601c) and replace with

new. See part number shown in the System Air

Controls Module (255761) section beginning on

page 44.

8. Follow steps in reverse order to reassemble.

Replace Solenoid Inlet Air Regulator

1. Remove Control Box Shrouds.

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

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

See page 36.

4. Pull out assembly.

21

20

19

ti19926a1

Repair

18 3A2989G

5. Disconnect air line.

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

7. Remove screws from quick clamps (601f) holding

air regulator assembly (601c) in place.

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

block (601e).

9. Remove regulator assembly (601d) and replace

with new. See part number shown in the System

Air Controls Module (255761) section beginning

on page 44.

10. Follow steps in reverse order to reassemble.

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

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

F

IG

. 5

604

640 631

633

611

617

615

613

606

618

603

609

629

625

620

621 622

617

612

616

610

607 608

635

633 634

635

629

627

628

627

632

636

626

638

632

637

619

618

630 641

646

644

645

642

642

643

647

613

Ref. 27

Repair

3A2989G 19

Dosing Valve Assembly

1. Follow Pressure Relief Procedure, page 7.

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

29). See F

IG

. 6.

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

bracket.

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

dosing valve outlet.

5. Disconnect pressure sensor (831) from dosing

valve. See page 50.

6. Remove dosing valves.

7. See Ratio Control Valve Assemblies on page 50

for disassembly illustration.

8. Follow steps in reverse order to reassemble dosing

valve assembly. See Ratio Control Valve Assem-

blies on page 50 for assembly illustration and spec-

ifications.

F

IG

. 6

29

28

55

55 54

85

31

37

36

Repair

20 3A2989G

Sensors

Replace Fluid Pressure Sensor

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

on system.

2. Follow Pressure Relief Procedure, page 7.

3. Open control box cover. See User Interface/Con-

trol Box, page 10.

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 recon-

nect 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. 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.

Replace Temperature (RTD) Sensors

This procedure applies to:

• Tank sensors mounted in the side of each tank near

the bottom (209).

• Glycol heater for hose outlet manifold sensor (100).

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

on system.

2. Follow Pressure Relief Procedure, page 7.

3. Disconnect the M8 cable connection.

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 out-

side 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.

Repair

3A2989G 21

Pump Assembly (System

Module)

Prior to servicing the pump assembly you must first

remove either the entire pump assembly or the displace-

ment pump and air motor individually.

Remove Pump Assembly

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.

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 F

IG

. 7 on page 22.

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

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.

7. Follow steps in reverse order to reinstall pump

assembly.

Remove Displacement Pump

Follow these instructions for removing only the displace-

ment pump; the air motor will remain installed.

1. Follow Pressure Relief Procedure, page 7.

2. Close ball valve on tank outlet.

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).

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).

6. Refer to the Xtreme Displacement Pump manual

311762 to service or repair the displacement pump.

7. Follow steps in reverse order to reinstall displace-

ment pump.

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).

ti8264a

2a

2c

2b

ti8301a

2d

2e

2f

Repair

22 3A2989G

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) hold-

ing air motor (2 or 3) to mounting bracket.

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)

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.

Solvent Pump

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.

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.

F

IG

. 7

2 or 3

5

4

Bracket

r__312359_313289_32

57

153

8

60

154

152

Repair

3A2989G 23

Heaters

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.

4. Reconnect fluid lines and electrical wiring.

Replace

1. Follow Pressure Relief Procedure, page 7.

2. Disconnect fluid lines and electrical wiring from fluid

heater.

3. System Module Heaters: See F

IG

. 8. Loosen four

mounting screws, lock washers, and plain washers

on back of heater (12 or 13) that secure it to the sys-

tem frame. Slide heater up and remove from mount-

ing 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.

F

IG

. 8: Heaters on System Module

12

13

12

Repair

24 3A2989G

Replace Radar Level Sensor

NOTE: Order radar level sensor kit 24T052. See Feed

Module (24P883) on page 40 for kit contents.

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.

1. With the tank empty, close the tank air supply ball

valve then open brass valve on tank lid to de-pres-

surize the tank. See F

IG

. 9.

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.

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

rod.

9. Tighten to approximately 25 - 30 in-lb (2.8 - 3.4

N•m). Do not over-tighten.

10. Reconnect sensor cable.

11. See Set Up a New Guided Level Sensor, page 25.

F

IG

. 9: Level Sensor Installation

WLD

Tank Air

Supply Ball

Valve location

(on other side

of panel)

Valve

Repair

3A2989G 25

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.

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

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.

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

• 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.

ti24380a

E

+

Repair

26 3A2989G

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 hour-

glass 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.

Electrical Schematics

3A2989G 27

Electrical Schematics

Simplified Electrical Schematic

Page 1 of 3

TB1

TB3

TB8

TB6

1

CB2

20A

126128

1

CB3

30A

126130

1

CB4

20A

126128

1

CB5

30A

126130

1

CB1

25A

126129

CB5-3

CB5-1

CB1-3

CB1-1

CB3-1

CB3-3

CB4-1

CB4-3

CB2-3

CB2-1

TB8-2

TB8-2

TB7-2

TB7-2

TB2-2

TB5-2

TB2-2

TB8-1

TB5-1

TB3-1

TB1-1

TB1-2

TB5-2

TB4-2

TB6-2

CB5-4

CB5-2

CB2-4

CB2-2

TB4-2

TB1-2

CB3-2

CB3-4

CB4-2

CB4-4

TB2

TB5

TB7

CB1-2

CB1-4

TB4

3

3

3

3

3

GND-2

24VDC

Power Supply

+L

GND

N

GND-3

N

L

+

-

-

230VAC

KEY:

DELTA

JUMPER

POSITIONS

N

L3

L2

L1

DISC1

Switch - 123969

4th

pole - 123968

FIELD

WIRE

SIDE

GRACO

WIRE

SIDE

RED +V

BLACK -V

TB3-2

16T147

PS1

380VAC

WYE

JUMPER

POSITIONS

2

4

2

4

2

4

2

4

2

4

TCMA-5L2

TCMA-5L1

SW3-3

SW1-1

TCMB-5L1

TCMB-5L2

TCMH5L1

TCMH-5L2

SW2-1

SW2-3

SW1-3

SW3-1

24VDC

POWER

Din rail

Electrical Schematics

28 3A2989G

Page 2 of 3

HOSE HEATER

4KW

245869

262853

16T525

16T525

16T859

AFLUID HEATER

5.4KW

NEMA

L6-20R

3

1

2

4

3

1

2

4

GND-2 GND-2 GND-2

BT

ANK HEATER

1.75KW

FLUSHHEATER

5K W

AT

ANKHEATER

1.75KW

NEMA

L6-30R

NEMA

L6-20R

NEMA

L6-20P

NEMA

L6-30P

NEMA

L6-20P

BLA CK

BLA CK

WHITE

WHITE

BFLUID HEATER

5.4KW

24P242

SW2-

1

SW2-

3

SW3-

1

SW3-

3

SW1-

3

SW1-

1

TC

MB-6

TCMB-6

TCMA-6

TCMB-5L2

GND-2

TCMB-5L1

SW1-

2

SW1-

4

SW2 -

2

SW3-

2

SW3-

4

SW2-

43

1

2

4

TCMB

255774

126511

126511

566

3

2

TCMB-

3L1

TCMB-

3L2

26

TCMH

255774

66

32

TCMH-

3L1

TCMH-

3L2

5

TCMH-5L2

GND-2

TCMH-5L1

TCMA

255774

66

32

TC

MA-3L1

TCMA-3L2

5

TCMA-5L2

GND-2

TCMA-5L1

TCMH-6

24VDC

POWER

TCMH-6 CAN

TCMA-6

TCMA-5L2

GND-2

TCMA-5L1

SW3-3

SW1-1

TCMB-5L1

TCMB-5L2

TCMH5L1

TCMH-5L2

SW2-1

SW2-3

SW1-3

SW3-1

16T147

Cable

125789

Cable

125789

SW1

Switch -15U423

15U423

15U423

SW2

Switch -

SW3

Sw

itch -

BLA CK

WH ITE

GND-2

BLACK

WHITE

GND-2

BLACK

WHITE

GND-2

BLACK

WHITE

Power

Distribution

Enclosure

125357

126427

262853

12

Splitter

125806

Electrical Schematics

3A2989G 29

Page 3 of 3

126495

124273

126494

126494

127172

24T052

24T052

127172

121806

121806

ALEVE LSENSOR

16T123

FCM1

Base - 289697

FCM - 2896961

5

7

2

BLEV

ELSENSOR

FCM1

126496

16T072

FCM1

CAN

USB1

Base - 289899

USB - 289900

DISPLAY SHIELD

15M483

DISPLAY

FRONT 255727

Air Motor Junction Box

NXT411

Linear Sensor - 256893

Reed Switch

ATankRTD

BT

ankRTD

Air Motor Junction Box

NXT411

Linear Sensor - 256893

Reed Switch

15M669

15M669

Dose A

Motor A

Dose B

Motor B

Stop - 121619

Power

Distribution

Enclosure

Control Enclosure

Manifold

Soleno id A

Soleno id B

15V779

Buzzer - 122000

Start - 121618

Manifold

256555

Manifold

256555

15M977 15M977

15U542 15U542

2

1

5

4

33

1

2

4

5

A BLUE B

GREEN

AFCM

255920

15M975 15M976

15M974

SETUP

KEY 121617

DISPLAY LCD

288997

121683

121683

15V778

USB

15R324

126381

126381

Electrical Schematics

30 3A2989G

XM PFP Air Logic Schematic

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Electrical Schematics

3A2989G 31

Feed Module Air Controls Schematic

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Parts

32 3A2989G

Parts

XM PFP System (262869, 24W626)

--- Not for sale.

◆Not shown.

‡ Not required for model 24W626.

* Qty. 2 required for 24W626.

Ref. Part Description Qty.

1 SYSTEM MODULE AND MIX LINE 1

262878 Model 262869

24W648 Model 24W626

2 FEED MODULES ASSEMBLY 1

24P202 Model 262869

24W628 Model 24W626

2a 24P883 FEED MODULE 2

2b* C20461 NIPPLE, reducing 1

2c‡ 100505 BUSHING 1

2d‡ 156849 NIPPLE 1

2f◆15U654 LABEL, A/B Identification 1

2g◆061134 HOSE, nylon 2.5

2h◆--- CABLE TIE 8

3 HEATED HOSE BUNDLE 1

16T121 Model 262869

16T122 Model 24W626

Ref. Part Description Qty.

‡

2c

2a

2a

‡

2d

*2b

3

1

ti20491a

1

Parts

3A2989G 33

XM PFP System (262869, 24W626) Subassemblies

Base System (262878, 24W648)

Page 1 of 5

46 85 95 96 61 97 99

61

NOTE: Apply pipe sealant to all non-swiveling pipe threads.

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.

98

ti20154a

Parts

34 3A2989G

Base System (262878, 24W648) page 2 of 5

10

11

45, 11

140

4, 5

43

140

43

36

44

1

41

57

151

8

76

94

36

44

102

103

104

32

33

61

35

38

39

61

30

101

67

67

67

54

54

60

Set air regulator to 85 psi

(590 kPa, 5.9 bar)

3

2

140a

143

144

145

146

147

148

154

155

153

152

150

149

9

ti20156a

Parts

3A2989G 35

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

27

67

59

67

105

118

60

29

28

56

55 54

85

31

120

37

36

ti20157a

Parts

36 3A2989G

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

110

26

25

21

20 22 24

23

18

17

19

16

17

52

40

109

15

112

111

108

116

115

9

114

113

117

114

ti20158b

133

86

132

Parts

3A2989G 37

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

54

54

78 79

85

127 120

12

107

106

13

100

82

34

15

12

9

ti20159b

64

93 100

132

133

87

Parts

38 3A2989G

Base System (262878, 24W648)

Ref Part Description Qty

1 --- FRAME 1

2 L180C9 PUMP; B side lower 1

3 L220C9 PUMP; A side lower 1

4 100133 WASHER, lock, 3/8 8

5 100101 SCREW, cap, hex head 8

6 256169 PLATE, solvent pump 1

7 121488 SCREW, hex head, flanged 2

8 W30CAS PUMP, solvent, 6.0 in, 75 cc; see

312794

1

9 112395 SCREW, cap, flange head 8

10 24N598 JUNCTION BOX; see page 45 1

11 113796 SCREW, flanged, hex head 6

12 262853 HEATER, Viscon HF 2

13 245869 HEATER, Viscon HP 1

14 24P899 FILTER, air, 1-1/4, assembly 1

15 126899 FITTING, compression, straight 2

16 255771 BOX, control, air/electric 1

17 112958 NUT, hex, flanged 10

18 255761 MODULE, air controls, upper 1

19 --- COVER, shroud, rear 1

20 256177 COVER, shroud, front 1

21 117623 NUT, cap, 3/8-16 4

22 --- LABEL, XM PFP 1

23 15T567 NUT, backup plate, hinge 4

24 15T568 DOOR, control shroud 1

25 121471 HINGE, friction, positioning 2

26 112380 SCREW, mach, pan head 8

27 113498 VALVE, safety, 110 psi 1

28 --- VALVE, ratio control, left; see

page 50

1

29 --- VALVE, ratio control, right; see

page 50

1

30 C19024 FITTING, elbow, swivel 1

31 111801 SCREW, cap, hex head 8

32 217430 FITTING, swivel, union, 90 degree 1

33 15T536 REGULATOR, air, 3/8 npt 1

34 100329 BUSHING, pipe 1

35 116504 FITTING, tee, run 1

36 C20461 FITTING, nipple, reducing, hex

Model 262878 3

Model 24W648 2

37 160032 FITTING, nipple

Model 262878 2

Model 24W648 4

38 116643 VALVE, safety, relief, air 1

39 101689 GAUGE, press, air 1

40 121688 CONNECTOR, 3/8 npti x 3/8 tube

ptc

1

41 115313 PLUG, tube 8

42 160327 FITTING, union adapter, 90

degree

2

43 15J277 CONTROL, de-ice, assembly 2

44 15M987 FITTING, elbow, 60 degree 2

45 117666 TERMINAL, ground 1

46 262893 MANIFOLD, mix; see manual

3A2988

1

47 --- SEALANT, pipe, stainless steel 1

48 --- LUBRICANT, thread 1

49 --- SEALANT, anaerobic 1

50 206995 FLUID, TSL, 1 qt. 1

52 108636 MUFFLER 1

53▲15X393 LABEL, warning, USB, all

languages

1

54 H75003 HOSE, coupled, 7250 psi,

0.50 in. ID, 3 ft

3

55 H75004 HOSE, coupled, 7250 psi,

0.50 in. ID, 4 ft

Model 262878 3

Model 24W648 5

56 H73806 HOSE, coupled, 7250 psi,

0.375 in. ID, 6 ft

(Model 262878 only)

1

57 H42506 HOSE, coupled, 4500 psi,

0.25 in. ID, 6 ft

1

58 205418 HOSE, coupled, air, 1/2 x 6 ft 2

59 16P244 HOSE, coupled, air, 5/16 x 3 ft 2

60 248208 HOSE, coupled, air, 5/16 x 4 ft 1

61◆159239 FITTING, nipple, pipe, reducing 4

62 16A004 FLASH DRIVE, USB, 2.0 1

63 121456 CONNECTOR, power, male, 3 pin 1

64 125806 CABLE, splitter, M8, 4-pin,

female/female/male, 1.5 m

1

65 126511 CABLE, GCA, M8, 4-pin, 1.5 m,

male/female

2

66 16T123 CABLE, GCA, CAN, male/female,

1.0 m

1

67 240900 HOSE, coupled, air, 30 in. x 3/4 in. 3

68 054172 TUBE, nylon, round, black, 1/4 in. 26.5

69 054175 TUBE, nylon, round, natural,

1/4 in.

8.5

70 551390 SIGHTGLASS, beaker, graduated 10

71 --- STRAP, tie 20

73 238909 WIRE, grounding assembly 1

74 C12508 TUBING, nylon, round, black,

3/8 in.

4.7

76 109025 TERMINAL, ring 1

79 16P856 LABEL, codes, alerts; all

languages

1

80 125357 CABLE, M8, 4-pin, male/female,

1 meter

1

81 126494 CABLE, M12, 5p, 4-wire with drain 2

82 126351 FITTING, compression,

thermocouple

1

Ref Part Description Qty

Parts

3A2989G 39

--- Not for sale.

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

◆Included in mix line and gun kit 24P833.

85◆H75002 HOSE, coupled, 7250 psi, 0.5 in.

(12 mm) ID, 2 ft

2

86 --- TUBE, 0.375 in. (9.5mm) ID blue

nylon

6

87 --- TUBE, 0.375 in. (12 mm) ID red

nylon

1.5

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,

10 ft

1

97◆H73803 HOSE, coupled, 7250 psi, 0.375

ID, 3 ft

1

98◆24P834 SWIVEL, straight 1

99◆262854 GUN, spray 1

100 126427 SENSOR, RTD, 1K ohm, 4 pin,

8in.

1

101 158990 MANIFOLD, air 1

102 165198 FITTING, nipple, reducing 1

103 121858 FITTING, elbow, 3/8 npte x 1/4

npte

1

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,

mount

1

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,

1/4 x 1

4

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

face flange base, 1/2-13

8

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

Ref Part Description Qty

131 16F366 FITTING, 1/4 in. x 1/4 in. push to

connect

2

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,

3 meter

2

136 122032 NUT, wire 2

137 15V778 CABLE, CAN, female-female,

20 in.

1

138 15V779 CABLE, CAN, female-female,

34 in.

1

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

swivel

1

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

Ref Part Description Qty

Parts

40 3A2989G

Feed Module (24P883)

Page 1 of 2

WLF

218

219

217

269

300

202

272

268, 215

265

266

215

206

271

270

273

267

243

201

247

216

213 211

209

207

208

210

211

212

213

213

222220

251

252

252

254

233

253

230

254

219a

298

297

Turns clockwise

as viewed from

the top

219

246

Parts

3A2989G 41

Page 2 of 2

ti20161c

225

224

249

250

250

276

226

224

277

227

229

228

261

223

224

260

259 258

257

231

262

227a

227b

227c

213

Parts

42 3A2989G

Feed Module (24P883)

--- 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

Ref Part Description Qty

201 --- FRAME 1

202 24M683 TANK, pressure, assembly 1

203 --- BOLT, hex head, 3.25 in. long,

5/8-11

4

204 111841 WASHER, plain 5/8 8

205 --- NUT, self-locking hex, nylon

insert, 5/8-11

4

206 16R869 COVER, tank wrap 1

207 --- BUSHING, pipe, hex head,

3/4 npt x 1/8 npt, steel

1

208 126351 FITTING, compression, thermo-

couple

1

209 126381 SENSOR, RTD, 1k ohm, 4 pin,

3in.

1

210 126898 FITTING, elbow 2

211 295847 FITTING, elbow, 90, 3/4 mpt 2

212 16T481 VALVE, check (see page 57) 1

213 157785 FITTING, swivel 4

215 171988 GASKET, inspection cap 1

216 16T619 FITTING, nipple, thread on one

end

1

217 24P885 AGITATOR, assembly, air (see

page 51)

1

218 --- MANIFOLD, assembly, air (see

page 53)

1

219 24T052 SENSOR ASSEMBLY, level 1

220 D11021 PUMP, diaphragm 1

221 100016 WASHER, lock 4

222 102040 NUT, lock, hex 4

223 262860 PANEL, assembly, air 1

224 113796 SCREW, flanged, hex head 8

225 16R871 BOTTLE, overflow, 1/2 npt 1

226 16T525 HEATER, fluid, 240V, Viscon LT 1

227◆262868 SUPPLY UNIT, 40:1, 0 volt, S20,

20L

1

227a P40DCS PUMP AND MOTOR, see man-

ual 312376

1

227b 257620 S20 RAM, see 313527 1

227c 257727 PLATEN, pail, see 313527 1

228 GC2041 WASHER, flat, std, 1/2 4

229 100017 SCREW, cap, hex head 4

230 117426 INSERT, tube 6

231 104633 VALVE, pilot 1

232 --- SEALANT, pipe, stainless steel 1

233 103475 FITTING, tee, pipe 1

234 --- TUBE, 0.375 in. (9.5mm) ID red

nylon

3.8

235 --- TUBE, 0.375 in. (9.5mm) ID blue

nylon

4.2

236 205418 HOSE, coupled 1

237 109130 HOSE, coupled, 48 in. 1

238 16P244 HOSE, coupled, 3 feet 3

239 15B772 HOSE, air, 18 inch 3

240 054172 TUBE, nylon, round 12

241 054753 TUBE, nylon, round, black 8

242 --- TUBE, 0.275 in. ID black nylon 5.5

243 115313 PLUG, tube 6

246 215241 HOSE, 3/4 in. x 6 ft, 6000 psi

(41 MPa, 410 bar)

1

247 16T244 VALVE, pressure relief, 3/4 in.

female npt

1

248 --- TIE, cable, 14 in. 20

249 108126 FITTING, tee, street 1

250 126899 FITTING, compression, straight 2

251 112782 ELBOW, swivel, 90 degree 1

252 126897 FITTING, elbow 2

253 115764 FITTING, elbow, 90 degree 1

254 190451 UNION, adapter 2

255 --- LABEL, part description 1

257 116395 FITTING, swivel, elbow 1

258 103656 FITTING, pipe, hex 1

259 198171 FITTING, elbow 1

260 593538 VALVE, shuttle 1/8 nptf 1

261 112781 ELBOW, swivel, 90 degree 1

262 24K976 MUFFLER, 1/4 npt 1

263 100505 BUSHING, pipe 1

264 155665 UNION, adapter 1

265 16R985 FITTING, nipple, 2 npt 1

266 16R983 FITTING, adapter, 2 npt to

3/4 npt

1

267 24P837 GASKET, agitator 1

268 210575 CAP, filler 1

269 16T245 COUPLING, shaft, one piece

clamp

1

270 16T396 SHAFT, agitator, lower 1

271 257604 BLADE ASSEMBLY 1

272 102726 PLUG, pipe headless 1

273 109212 SCREW, socket cap head 1

274 115219 FITTING, tee, 1/4 npt 1

275 262820 KIT, fluid outlet, flexible 1

276 126900 CONNECTOR, male 1

277 126692 CONNECTOR, male 1

296 156172 FITTING, union, swivel 1

297 260067 FITTING, strain relief 1

298★127172 CABLE, M12, 5-pin, 4-wire 1

299 102726 PLUG, pipe, headless 1

300 117571 GASKET, santoprene 1

Ref Part Description Qty

Parts

3A2989G 43

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)

--- Not for sale.

◆Not shown.

310b

310c

302 (red)

305 (blue)

301

308

306

310a

302

305

303

303

307

304

309

ti20243a

Ref Part Description Qty

301 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

nylon

2

303 H42550 HOSE, coupled, 4500 psi, 1/4 in. ID,

50 ft (15.2 m)

1

304 --- LABEL, identification 1

305 16X028 KIT, tube, 0.375 in. (9.5mm) ID blue

nylon

2

306 --- TAPE, electrical 1

307 --- TUBE, insulation, 2-5/8 in. ID, 50 ft

(15.2 m)

1

308 H75050 HOSE, coupled, 7250 psi, 1/2 in. ID,

50 ft (15.2 m); Model 16T121 only

1

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

310c 126896 ELBOW, 1/2 in. tube x 1/2 nptf 2

311◆16U111 KIT, fittings, hose connection 1

311a◆C20487 NIPPLE, hex 2

311b◆158491 NIPPLE 1

311c◆156823 UNION, swivel 2

311d◆156971 NIPPLE, short 1

Ref Part Description Qty

Parts

44 3A2989G

Base System (262878, 24W648) Subassemblies

System Air Controls Module (255761)

NOTE: For Feed Module Air Panel (262860) parts, see page 55.

★Parts included in Air Controls Kit 255772 (purchase sepa-

rately).

--- Not for sale.

604

640 631

633

611

617

615

613

606

618

603

609

629

625

620

621 622

617

612

616

610

607 608

635

633 634

635

629

627

628

627

632

636

626

638

632

637

619

618

630 641

646

644

645

642

642

643

647

613

Ref. 27

Ref. Part Description Qty.

603 157350 NIPPLE, pipe; 1/2 x 3/8 npt 1

604 108307 ELBOW, pipe, male 1

606 101689 GAUGE, press, air 2

607 117346 VALVE, ball, vented 1

608 114316 ELBOW, male, swivel 1

609* 114109 ELBOW, male, swivel; 1/4 OD tube 2

610 158962 ELBOW, street; 1/4(f) x 1/8(m) 1

611 116643 VALVE, safety, relief, air 1

612 100721 PLUG, pipe 3

613 119992 PIPE, nipple; 3/4 x 3/4 npt 2

615 156589 ADAPTER, union; 90 deg. 1

616 113911 GAUGE, pressure, air 1

617 160327 ADAPTER, union; 90 deg. 2

618 15T119 LABEL, control 1

619 --- BRACKET, air controls 1

620 15R437 BRACKET, adapter, air controls 2

621 121432 SCREW, machine, hex flat head 2

622 115942 NUT, hex, flange head 4

625 116513 REGULATOR, air 1

626 121457 VALVE, ball, air, panel mounted 1

627 121424 GAUGE, pressure, panel mount, 1.5 in. 1

628 100451 COUPLING 1

629 114151 ELBOW, male, swivel 2

630 100264 SCREW, machine, pan head 2

631 116514 NUT, regulator 1

632 054760 TUBE, polyurethane, round, black; 1.25

in.

-

633 --- TUBE, polyurethane, round; 0.6 ft. -

634 100840 ELBOW, street 1

635 162453 FITTING; 1/4 npsm x 1/4 npt 2

636 114114 ELBOW, male, swivel 1

637 114128 ELBOW, male, swivel 1

638 164259 ELBOW, street 1

640★122336 NUT, panel, regulator 1

641★113440 ADAPTER 2

642★113431 CLAMP, quick 4

643★113442 BLOCK, porting 2

644★15R488 REGULATOR 1

644a 123454 FILTER, element; 5 micron 1

645★15R487 REGULATOR 1

646★15R486 MUFFLER 1

647★15R485 VALVE, dual pilot 1

Ref. Part Description Qty.

Parts

3A2989G 45

Junction Box (24N598)

B HOSE A

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.

4

416

417,

407, 408 405b 406 403 407 420 421 426, 427

415, 445

413, 414, 443

402 403

404

418, 419, 423

403, 446

412

411

410

409

401

425

442

405

405a

405f 405c 405e

4

ti20155a

444

442

422,

439

Parts

46 3A2989G

Junction Box (24N598)

--- Not for sale.

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

zBase 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.

Ref Part Description Qty

401 --- ENCLOSURE 1

402 --- BRACKET, module 3

403 114231 NUT, lock, hex 16

404◆255774 MODULE, GCA, HPTCM 3

405 --- MODULE, breaker 1

405a 126382 BLOCK, terminal 8

405b 126129 BREAKER, 25A 1

405c 126130 BREAKER, 30A 2

405d 126684 JUMPER, red 3

405e 126453 POWER SUPPLY, 24V 1

405f 126128 BREAKER, 20A 2

406 121603 GRIP, cord, 0.51-0.71, 3/4 6

407 255047 BUSHING, strain relief, M40

thread

2

408 255048 NUT, strain relief, M40 thread 2

409 15U423 SWITCH, 2p, 25a 3

410 123967 KNOB, operator disconnect 1

411 123968 SWITCH, disconnect, 100 amp 1

412 123969 SWITCH, disconnect, 100 amp 1

413† 289697 MODULE, GCA, cube, base 1

414 104371 SCREW, cap sch 10 x 0.375 4

415z† 289696 MODULE, GCA, cube, FCM 1

416 117666 TERMINAL, ground 1

417 115942 NUT, hex, flange head 1

418 15U651 BRACKET, high power, GCA 6

419 117831 SCREW, machine, pan head 12

420 --- BAR, ground 1

421 109466 NUT, lock, hex 2

422 104387 SCREW, machine, pan head 4

423 113161 SCREW, flange, hex head 6

425 126496 CONNECTOR, thru, M12, male x

female, reverse key

1

426 --- MODULE, solenoid 1

426a 121636 VALVE, solenoid 2

426b 15A798 GASKET, outlet 1

426c 15A799 GASKET, inlet 1

427 106084 SCREW, machine, pan head 2

428 125789 CABLE, CAN, female / female,

0.5 m

2

429 123422 CABLE, CAN, 5-pin, female /

female, 0.4 m

2

430 121615 HARNESS, splitter, M8, 4-pin,

female/female/male, 3 m

1

432 126495 CABLE, splitter, 4-20ma, 2 circuit 1

433 124273 CONNECTOR, splitter 1

434 --- STRAP, tie 14

435 126494 CABLE, M12, 5p, 4wire with drain 2

436 121806 CABLE, solenoid 2

437 --- STRIP, foam, neoprene 10

438 16T147 CABLE, can power, M12 female,

pigtail

1

439 16P626 LATCH, enclosure 4

440▲16T278 LABEL, multi-purpose; including

warnings text, shock arrow,

ground symbol, and various infor-

mational stickers

1

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

Ref Part Description Qty

Parts

3A2989G 47

Control Box (255771)

501

502

504c

504a, 504d

532

532 538

521

504e

504f

510

528

529

530

540

541

543

515

524, 525

517

507

535

514

509

526

508

545

503

502

523

522

520

536

504g

501

538

537

544

533 534 526

527

504b

542

542

551

543

504h

539

519c

543

526

ti18050a

546

Ref. Part Description

Qty

.

501 --- BOX, control 1

502 --- LABEL, control display 1

503† 24R899 KIT, replacement, USB; includes

519 and 506

1

504z257484 MODULE, display, kit

504a 15M483 SHIELD, membrane, display (qty.

10)

1

504b --- SCREW, pan head; #6 x 7/8 in. 4

z504c 288997 CASE, rear, display module, IS

version

1

504d 255727 CASE, front, data module 1

504e 277463 COVER, access, low level display 1

504f 113768 SCREW, socket, flat head 4

504g 15R458 GASKET, control, front panel 1

▲504h 15W958 LABEL, warning, battery 1

505† 24R897 KIt, replacement, display; includes

504 and 506

1

506* 16P644 TOKEN, software 1

507† 24R898 KIT, replacement, FCM; includes

518 and 506

1

508 --- SCREW, pan head 4

509 256555 MODULE, solenoid, IS version 1

509a 121636 VALVE, solenoid, din connector 4

509b 15A798 GASKET, solenoid, outlet 1

509c 15A799 GASKET, solenoid, inlet/exhaust 1

510 106084 SCREW, machine, pan head 2

514 15R379 GASKET, box, control 1

515 --- LABEL 1

516❄15B056 LABEL, air motor/dosing valve 1

517 122000 ALARM, panel mount 1

518z255920 MODULE, fluid control 1

Ref. Part Description

Qty

.

Parts

48 3A2989G

▲Replacement Danger and Warning labels, tags, and

cards are available at no cost.

--- Not for sale.

❄Not shown.

zBase 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.

519z257088 MODULE, USB, assy.

519a 289899 BASE 1

z519b 289900 MODULE, USB 1

519c 277674 DOOR, module 1

520 121618 SWITCH, start, push button,

green

1

521 15R324 HARNESS, USB, plug/bulkhead;

32 in.

1

522 121619 SWITCH, stop, push button, red 1

523 121617 SWITCH, 2 position, key, controls 1

523a❄123412 KEY, replacement (pair)

524 117745 BUSHING, strain relief 1

525 117625 NUT, locking 1

526 113505 NUT, keps, hex head 6

527 15B090 WIRE, grounding, door 1

528 --- WASHER, lock, external, 1/4 in. 1

529 15R343 CLAMP, ground, electrical 1

530 --- WIRE, copper 3

531❄172953 LABEL, designation 2

532 120493 LATCH, mounting 3

533 15H189 BOOT, wire feed through 1

534 15G816 COVER, plate, wire 1

535 110637 SCREW, machine, pan head 4

536 15R325 COVER, dust, bulkhead

receptacle

1

537 120494 BLOCK, switch, normally open 2

538 120495 BLOCK, switch, normally closed 1

539 15M974 HARNESS, key switch 1

540 15M975 HARNESS, start/alarm 1

541 15M976 HARNESS, stop 1

542 15M977 HARNESS, solenoid 2

543 121988 RETAINER, routing, wire harness 4

544 195875 SCREW, machine, pan head 1

545 102063 WASHER, lock 1

546 15U542 CABLE, motor 2

551▲LABEL, warning, USB 1

15X214 English

15X393 All languages

552❄122829 CONDUIT; 0.75 ft. -

Ref. Part Description

Qty

.

Parts

3A2989G 49

Air Filter (24P899)

--- Not for sale.

◆Not shown.

ti20218a

Apply PTFE tape and/or pipe sealant to all

non-swiveling pipe threads.

Orient fittings approximately as shown.

1

2

706

707

711

703

704

711

705

702

701

702

703

704

708

703

709

Ref Part Description Qty

701 16T236 FILTER, air, 1-1/4, auto drain 1

701a◆106204 FILTER ELEMENT 1

702 C19662 BUSHING, 1-1/4 x 1 npt carbon

steel

2

703 110300 FITTING, elbow, street, pipe 3

704 158585 FITTING, nipple 2

705 16R951 MANIFOLD, air distribution 1

706 157785 FITTING, swivel 1

707 C19024 FITTING, elbow, swivel 1

708 113163 VALVE, ball, vented, 1.00 in. 1

709 160022 FITTING, union, adapter 1

710 --- SEALANT, pipe, stainless steel 1

711 100361 PLUG, pipe 2

Parts

50 3A2989G

Ratio Control Valve Assemblies

† See Dosing Valve Instructions - Parts manual refer-

enced on page 3 for further details.

Apply pipe sealant to all non-swiveling pipe threads.

Position valve (832) with barbed fitting (833) oriented as shown,

position elbow (837) as shown.

Torque until nut (831) bottoms out in housing.

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

open position.

1

8

14

15

836

855

852

852

854

853

839

831

1

15

1

1

1

1

1

14

832

8

833

8

851

857 1

856

836 1

8371

840 1

8

801

ti20219a

858

Ref Part Description Qty

801† 255478 VALVE, dosing 1

831 15M669 SENSOR, pressure, fluid outlet 1

832 262872 VALVE, pressure, bleed, PFP 1

833 116746 FITTING, barbed, plated 1

836 156684 FITTING, union, adapter 2

837 15M987 FITTING, elbow, 60 degree 1

839 121399 PACKING, o-ring 1

840 158491 FITTING, nipple

(B side only - Qty 1)

(A side only - Qty 2)

851 116750 TUBE, nylon 1

852 158683 FITTING, elbow, 90 degree 2

853 159239 FITTING, nipple, pipe, reducing

(B side only)

1

854 156877 FITTING, nipple, long 1

855 262739 VALVE, ball, 1/2 in. 1

856 16T481 VALVE, check; see page 57 1

857 502033 FITTING, bushing, pipe 1

858 157785 FITTING, swivel 1

Ref Part Description Qty

Parts

3A2989G 51

Feed Module (24P883) Sub-Assemblies

Air Powered Agitator (24P885)

Apply pipe sealant to all non-swiveling pipe threads.

Apply low strength threadlocker.

Apply blue thread locker.

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).

Leave a 0.015 in. gap between each half of couplings (910,

911, 916, 917).

When ordering a replacement coupling: Remove set screw

supplied with couplings (910, 916) and discard. Replace with

set screw (931).

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

housing (902).

1

2

3

4

5

7

8

917

918

923

924

925

922

919

921

915

907

916

914

912

913

911

910

909

905

906

908

913

905

904

903

902

901

5

2

2

5

7

915

43

3

5

7

5

3

8

7

7

Parts

52 3A2989G

Air Powered Agitator (24P885)

--- Not for sale.

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

Ref Part Description Qty

901 16P919 SHAFT, agitator, upper 1

902 16U219 HOUSING, agitator 1

903 --- SEAL, 0.875 in. ID x 1.125 in. OD,

PTFE

1

904 --- SPACER, shaft, agitator, ASME 1

905 122774 BEARING, ball, 3/4bore x 1-3/4 dia. x

1/2

2

906 16P920 HOUSING, bearing, agitator 1

907 --- SCREW, socket head set screw,

5/16-18 x 0.75

2

908 112222 SCREW, socket cap head 4

909 --- RING, retaining, external, 0.750 in. 1

910 122761 HOUSING, alignment, hub 1

911 122760 COUPLING, alignment, disk, TPE 1

912 16P922 BRACKET, adapter, agitator 1

913 C19209 WASHER, lock 8

914 101682 SCREW, socket cap head 4

915 181794 GEAR, reducer 1

916 16P923 COUPLER, adapter 1

917 100828 COUPLING, flexible 1

918 16T063 COLLAR, mounting 1

919 116940 SCREW, cap, socket head, 5/16-18 2

920 181849 COLLAR 1

921 101118 SCREW 2

922 111310 MOTOR, air, rotary 1

923 115841 FITTING, elbow 1

924 206264 VALVE, needle 1

925 191872 FITTING, nipple, reducing 1

926 --- SEALANT, pipe, stainless steel 1

927 --- SEALANT, low strength thread locker 1

928 --- SEALANT, blue thread locker 1

929▲15A722 TAG, warning, agitator 1

930▲16A614 TAG, label, caution 1

Parts

3A2989G 53

Tank Air Manifold Assembly

--- Not for sale.

1008

Apply pipe sealant to all non-swiveling pipe threads.

Orient all fittings as shown.

1

2

1001

1005

1013

1004

1003

1002

100610071003

1010

1012

1011

1013

1009

1008

Ref Part Description Qty

1001 189016 MANIFOLD, air, inlet 1

1002 155665 UNION, adapter 1

1003 156849 PIPE, nipple 2

1004 214847 LUBRICATOR, air line 1

1005 165198 FITTING, nipple, reducing 1

1006 100840 FITTING, elbow, street 1

1007 103347 VALVE, safety, 100 psi 1

1008 156971 FITTING, nipple, short 2

1009 108638 FITTING, pipe, tee 1

1010 101759 FITTING, drain cock 1

1011 101754 PLUG, pipe 1

1012 100139 PLUG, pipe 1

1013 100030 BUSHING 1

1014 111856 FITTING, elbow, street 1

1015 --- SEALANT, pipe, stainless steel 1

Parts

54 3A2989G

Static Mixer (16T316)

--- Not for sale.

1303

1303

1301

1302

Apply pipe sealant to all non-swiveling pipe threads.

1

Ref Part Description Qty

1301 --- TUBE, mixer 1

1302 24P886 MIXER, 12 element, stainless steel 1

1303 16T315 BUSHING, reducing 3/4 nptf x

1/2 npt

2

1304 --- SEALANT, pipe, stainless steel 1

Parts

3A2989G 55

Feed Module Air Panel (262860)

NOTE: For System Air Controls Module (255761) parts, see page 44.

Apply pipe sealant to all non-swiveling pipe threads.

1

1122

1121

1122

1123

1103

1121

1122

1102

1101

1103

1104

1113

1114

1130

1129

1110

1105

1106

1125

1127

1128

1109

1111

1113

1114

1117

1115

1116

1120

1111

1118

1119

Parts

56 3A2989G

Air Panel (262860)

--- Not for sale.

Ref Part Description Qty

1101 --- BRACKET, air control 1

1102 --- LABEL, instructions 1

1103 121424 GAUGE, pressure, panel mount,

1.5 in.

1

1104 15T498 FITTING, 90 degree, swivel,

5/32 in. tee x 1/8 in. female npt

1

1105 116513 REGULATOR, air 1

1106 121141 FITTING, elbow, swivel, 3/8 tee,

1/4 in. male npt

1

1109 198171 FITTING, elbow 1

1110 100403 PLUG, pipe 1

1111 121457 VALVE, ball, air, panel mounted 2

1113 155699 FITTING, elbow, street 3

1114 165198 FITTING, nipple, reducing 3

1115 104984 FITTING, tee, pipe 1

1116 157705 UNION, swivel 1

1117 156971 FITTING, nipple, short 1

1118 206264 VALVE, needle 1

1119 114367 FITTING, tube, qd, 90 degree

elbow

1

1120 109544 FITTING, elbow, pipe, male 1

1121 110914 VALVE, button, push 1

1122 100264 SCREW, mach, panhead 4

1123 116514 NUT, regulator mount 1

1124 109193 FITTING, tube, male, elbow 2

1125 16F151 FITTING, elbow, swivel, 3/8 tee,

3/8 npt

1

1126 --- SEALANT, pipe, stainless steel 1

1127 054134 TUBE, nylon, 3/8 in. OD 1.1

1128 517305 TUBE, nylon, 5/32 in. OD 0.7

1129 106495 VALVE, check, brass, 1/4 MBE 1

1130 100840 FITTING, elbow, street 1

Parts

3A2989G 57

Check Valve (16T481)

--- Not for sale.

Flexible Fluid Connection Kit (262820)

Ref Part Description Qty

1201 --- NUT, seat 1

1202 102595 PACKING, o-ring 1

1203 100279 BALL, metallic 1

1204 108361 SPRING, compression 1

1205 --- HOUSING, ball check 1

1206 181492 GUIDE, ball 3

1207 181535 RETAINER, spring 1

1205

1201

1207 1204 1203

1202

1206

1

Torque to 75-80 ft-lb (102-108 N•m).

1

Ref Part Description Qty

1401 120291 PIPE, elbow female 1

1402 125995 FITTING, hose, barbed, 1-1/2 npt 2

1403 126320 HOSE, 1-1/2 ID, 200 psi, 3 ft 1

1404 126889 CLAMP, hose 2

1405 121440 VALVE, ball, 1-1/2 npt 1

1406 121441 FITTING, nipple, hex, 1-1/2 npt 1

1407 121443 FITTING, tee, 1-1/2npt 1

1408 101496 BUSHING, pipe 1

1409 104663 PLUG, pipe 1

1410 121445 SWIVEL, reducing, 1-1/2 x 1-1/4 1

1411 121436 FITTING, swivel, male, 2 in. 1

1412 121435 FITTING, nipple, hex, 2 in. 1

1406

1405

1402

1404

1403

1404

1402

1401

1411

1412

1410

1408

1409

1407

Technical Data

58 3A2989G

Technical Data

XM PFP

US Metric

Mix Ratio Range 1:1-10:1 (in 0.01 increments)

Ratio Tolerance Range (before alarm) +/- 5%

Maximum Flow Rate (measured with oil) 3 gallons per minute 13.6 liters per minute

Fluid Viscosity Range 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

Materials

6000 psi 41 MPa, 414 bar

Maximum Fluid Working Pressure for Flushing

Fluid

4500 psi 31 MPa, 7 bar

Maximum Fluid Working Pressure for Heating

Fluid

100 psi 0.7 MPa, 7 bar

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 meter

3

/min

Maximum 250 scfm 7.1 meter

3

/min

Typical Application 125-175 scfm 3.5-5.0 meter

3

/min

Power Requirements

Voltage (can be set with jumpers) Option 1: 220-240V, 3 phase DELTA (3 wire plus ground)

Option 2: 380-400V, 3 phase WYE (4 wire including neutral

plus ground)

Wattage 18,400 watts (23,400 with optional flush water heater)

Amps 240V, 3-phase models: 65 Amps per phase full load

380V, 3-phase models: 38 Amps per phase full load

Technical Data

3A2989G 59

Wetted Parts

Suction Tube (Flush) Aluminum

Tanks Stainless Steel

Flush Pump Carbide, PTFE, stainless steel, UHMWPE

Hoses Nylon

Pumps (A, B and Feed Pail) Carbon steel, alloy steel, 303, 440, 17-ph grades stainless

steel, zinc and nickel plating, ductile iron, tungsten carbide,

PTFE

Dosing Valves Carbon Steel, nickel plating, carbide, polyethylene, leather

Manifold Carbon steel, nickel plating, carbide, 302 stainless steel,

PTFE, UHMWPE

Mixer Stainless steel housing with stainless elements

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.

XM PFP

US Metric

Technical Data

60 3A2989G

Dimensions

Min: 70 in.

(1780 mm)

Max: 84 in.

(2130 mm)

76 in.

(1930 mm)

52 in.

(1320 mm)

WLE

Min: 70 in.

(1780 mm)

Max: 84 in.

(3130 mm)

38 in.

(965 mm)

104 in.

(2640 mm)

Notes

3A2989G 61

Notes

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

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