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Graco XP50s-hf, Operation, Repair, And Parts

The Graco XP50s-hf is a high-quality, versatile industrial paint sprayer designed for professionals. This comprehensive and user-friendly product emphasizes ease of operation, repair, and parts replacement. To ensure efficiency and cost-effectiveness, a detailed manual is available for free download at manualshive.com, providing step-by-step instructions for optimal performance.

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3A6283F

Contents

Related Manuals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Isocyanate (ISO) Information . . . . . . . . . . . . . . . . . . . . 7

Isocyanate Conditions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Keep Components A and B Separate   . . . . . . . . . . . . . . . . . . . 7
Moisture Sensitivity of Isocyanates   . . . . . . . . . . . . . . . . . . . . . 8
Changing Materials   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Over Pressure Protection   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

XPs-hf Systems  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Approvals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Component Identification   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

XPs-hf Proportioners (Model 577101 shown)   . . . . . . . . . . . . 15
Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fluid Control Assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main Air Controls  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Heated Hopper Assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

System Components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Air Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fluid Line Components   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pumps   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Setup  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Initial System Setup  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Proper Lifting of Sprayer   . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Grounding   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Connect Power Source   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connect Explosion-Proof Heaters  . . . . . . . . . . . . . . . . . . . . . 27
Motor Position   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connect Air Supply   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Connecting Heated Hose to Proportioner   . . . . . . . . . . . . . . . 29
Connect Static Mixers, Gun, and Hoses   . . . . . . . . . . . . . . . . 30
Add Heating Fluid to Heated Hoppers  . . . . . . . . . . . . . . . . . . 30
Agitators (ED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Feed Pumps (EE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Solvent Pump (BA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
XP Displacement Pumps (D)  . . . . . . . . . . . . . . . . . . . . . . . . . 33
Add Heating Fluid to Hoses  . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Operation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Flush Before Using Equipment   . . . . . . . . . . . . . . . . . . . . . . . 34
Prime the Empty System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Startup/Recirculate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Prime Solvent Pump   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Prime the Material Lines   . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Spray  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Adjust the Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Pressure Relief Procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Flushing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Overnight Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
System Verification   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Mix and Integration Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Appearance Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Monitor Fluid Supply   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Check Pot Life  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Ratio Check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Maintenance   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50

Hose Electrical Resistance  . . . . . . . . . . . . . . . . . . . . . . . . . .  50
Filters   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50
Cleaning Procedure   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50
Change the Mix Ratio  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50
Clean Inlet Strainer Screen . . . . . . . . . . . . . . . . . . . . . . . . . .  51
Check Heating Fluid Level  . . . . . . . . . . . . . . . . . . . . . . . . . .  51
Drain Heating Fluid  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  51
Feed Pumps  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  52
Solvent Pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  52
XP Displacement Pumps   . . . . . . . . . . . . . . . . . . . . . . . . . . .  52
Agitators  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  52

Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  53

Pump Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  55

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  56

Pump Assembly Repair   . . . . . . . . . . . . . . . . . . . . . . . . . . . .  56
Recirculation Manifold with Over Pressure Relief Valves . . .  57
Replace Over Pressure Relief Valves   . . . . . . . . . . . . . . . . .  58

Parts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  60

XP50s-hf and XP70s-hf Proportioner  . . . . . . . . . . . . . . . . . .  60
XP50s-hf and XP70s-hf Proportioners (Continued)  . . . . . . .  61
XP50s-hf and XP70s-hf Proportioners (Continued)  . . . . . . .  62
Water Jacketed Heated Hose Packages   . . . . . . . . . . . . . . .  64
Non-Heated Hose Packages   . . . . . . . . . . . . . . . . . . . . . . . .  66
Non-Hazardous Location Electric Heated Hose Packages   .  68
Hazardous Location Electric Heated Hose Packages   . . . . .  69
Air Control Filter 25N583 Parts . . . . . . . . . . . . . . . . . . . . . . .  71
Air Control Regulator 25N575 Parts  . . . . . . . . . . . . . . . . . . .  72
Solvent Pump 262392 Parts  . . . . . . . . . . . . . . . . . . . . . . . . .  73
Solvent Air Control 24F126 Parts  . . . . . . . . . . . . . . . . . . . . .  74
Heater Block Remote Manifold Kit  . . . . . . . . . . . . . . . . . . . .  75
Material Recirculation Manifold with Over Pressure Relief 

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  76

Diaphragm Pump 273093 Parts  . . . . . . . . . . . . . . . . . . . . . .  77
XP-hf Pump Assembly Parts   . . . . . . . . . . . . . . . . . . . . . . . .  78

Recommended Spare Parts  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80
Accessories and Kits  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  81
Dimensions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  82

System Dimensions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  82

Technical Specifications   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  83
Recycling and Disposal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  85

End of Product Life  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  85

California Proposition 65  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  85
Graco Standard Warranty   . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  86

Summary of Contents for XP50s-hf

Page 1: ...ixing and spraying two component coatings For professional use only See page 10 for model information and working pressures See page 11 for component approvals Important Safety Instructions Read all warnings and instructions in this manual and in related manuals before using the equipment Save these instructions 3A6283F EN WL D ...

Page 2: ...m Verification 49 Mix and Integration Tests 49 Appearance Test 49 Monitor Fluid Supply 49 Check Pot Life 49 Ratio Check 49 Maintenance 50 Hose Electrical Resistance 50 Filters 50 Seals 50 Cleaning Procedure 50 Change the Mix Ratio 50 Clean Inlet Strainer Screen 51 Check Heating Fluid Level 51 Drain Heating Fluid 51 Feed Pumps 52 Solvent Pump 52 XP Displacement Pumps 52 Agitators 52 Troubleshooting...

Page 3: ...ion Box Installation Parts Solvent Flush 310863 Feed and Solvent Flush Kits Instructions Parts 312794 Merkur Pump Assembly Instructions Parts Accessories and Kits 3A3320 XP and XP hf PressureTrak Kit Instruction Parts 3A1331 XP Pressure Monitor Kit Instructions Parts 312769 Feed Pump and Agitator Kits Instructions Parts 3A0421 Ratio Check Kit Instructions Parts 3A2573 Gun Splitter Valve Instructio...

Page 4: ...mable fumes such as solvent and paint fumes in work area can ignite or explode Paint or solvent flowing through the equipment can cause static sparking 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 sparking Ground all equipment in the work ...

Page 5: ... 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 ENTANGLEMENT HAZARD Rotating parts can cause serious injury Keep clear of moving parts Do not operate equipment with protective guards or covers removed Do not wear loose clothing jewelry or long hair while opera...

Page 6: ...equipment Keep children and animals away from work area Comply with all applicable safety regulations PERSONAL PROTECTIVE EQUIPMENT Always wear appropriate personal protective equipment and cover all skin when spraying servicing equipment or when in the work area Protective equipment helps prevent serious injury including long term exposure inhalation of toxic fumes mists or vapors allergic reacti...

Page 7: ...maintained and adjusted according to instructions in the manual To prevent inhalation of isocyanate mists vapors and atomized particulates everyone in the work area must wear appropriate respiratory protection Always wear a properly fitting respirator which may include a supplied air respirator Ventilate the work area according to instructions in the fluid manufacturer s SDSs Avoid all skin contac...

Page 8: ... reservoir if installed filled with appropriate lubricant The lubricant creates a barrier between the ISO and the atmosphere Use only moisture proof hoses compatible with ISO Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use Always lubricate threaded parts with an appropriate lubricant when reassembling NOTICE Changing the material types ...

Page 9: ... setting materials less than 10 minute pot life a remote mix manifold must be used The mix manifold is separated from the recirculation manifold and mounted on a remote carriage Heated hoses are used to prevent temperature loss in the materials while flowing to the remotely mounted mix manifold Systems are configured to connect either a water heated hose or an electric heated hose Heated hoses are...

Page 10: ...uid Output cc cycle Fluid Flow at 40 cpm gpm lpm Over Pressure Relief Valve Maximum Air Working Pressure psi MPa bar Fluid to Air Pressure Ratio Maximum Fluid Working Pressure psi MPa bar 5771xx 1 1 L14AC0 L14AC0 290 3 0 11 3 Silver 100 0 7 7 71 1 7100 49 490 5772xx 2 1 L18AC0 L090C0 270 2 8 10 6 Silver 95 0 65 6 5 76 1 7250 50 500 5773xx 3 1 L22XC0 L072C0 292 3 0 11 3 Silver 100 0 7 7 71 1 7100 4...

Page 11: ...ivision 1 xxxx2x 480 Non Hazardous Ordinary Locations xxxx3x 480 Class I Division 1 Sixth Digit Water Hose Heat with Circulation Pump Electric Heated Hose xxxxx1 xxxxx2 xxxxx3 System Approvals 57xx0x 57xx1x System is intended for hazardous locations with the classification of Class I Division 1 Group D T3 0 C to 54 C 57xx2x 57xx3x System is intended for hazardous locations with the classification ...

Page 12: ... 480V HF Ex 24W248 240V HF Ex 24P016 240V HF Non Hazardous 26C475 480V HF Non Hazardous 9902471 Class 1 Division 1 Groups C D T3 Ta 20 C to 60 C Certificate No 18 KA4B0 0072X IECEx Ratings EX db IIB T4 Gb IECEx Certificate No IECEx ETL 14 0046X Ta 20 C to 60 C ATEX Ratings ATEX Certificate No ITS14ATEX18155X II 2 G Ex db IIB T4 Gb 9902471 Certified to CAN USA C22 2 No 88 Conforms to UL499 ...

Page 13: ...tion Electrical Enclosure 26C582 480V Junction Box 26C904 480V Junction Box Electric Hose Heat 26C580 240V Junction Box 26C899 240V Junction Box Electric Hose Heat Heated Hopper Assembly North American Location European Atmosphere Approvals Component Description Non Hazardous Hazardous Non Explosive Explosive 25P239 Immersion Heaters 480V 25N577 Immersion Heaters 240V 25N584 5 1 Monark Pump 25N588...

Page 14: ...Atmosphere Approvals Component Description Non Hazardous Hazardous Non Explosive Explosive 245864 480V HP Hazardous 245863 240V HP Hazardous 245869 240V HP Non Hazardous 245870 480V HP Non Hazardous II 2 G Ex h T5 Gb 9902471 Class 1 Division 1 Groups C D T3 Ta 20 C to 60 C Certificate No 18 KA4B0 0072X IECEx Ratings EX db IIB T4 Gb IECEx Certificate No IECEx ETL 14 0046X Ta 20 C to 60 C ATEX Ratin...

Page 15: ...Component Identification 3A6283F 15 Component Identification XPs hf Proportioners Model 577101 shown WL F 5 7 6 9 8 8 3 7 3 1 XP hf Pump Assembly ...

Page 16: ... page 18 P Pump Tie Rods R Motor Adapter Plate S Adjustable Packing Nuts with Wet Cups T Yoke with Rod Bearings U Recirculation Lines X Motor Position Indicator Bracket V Connecting Rod Nut Y Over Pressure Rupture Disk for pumps that are 145cc or smaller BA Solvent Pump see page 19 ZC Electrical Enclosure see page 17 ZF Hot Water Reservoir if equipped ZG Diaphragm Pump if equipped ZP Diaphragm Pum...

Page 17: ...y ZJ Electric Heated Hose Temperature Controller Display Non hazardous locations only ZK Hose Heater Harness Entry Point ZL Thermocouple Sensor Entry Point ZM Fluid Heater and Hopper Heater Harness Entry Point ZN Hopper Heater Switches ZR Electric Heated Hose Temperature Controller Hazardous locations only ZS Main Power Entry Point ZW Temperature Display Hazardous locations only WL E 1 03 03 1 6 0...

Page 18: ...x Manifold Check Valves AL Solvent Inlet Check Valve AM Automatic Spring Loaded Color Coded Over Pressure Relief Valves with grease fittings AN Static Mixer Tubes 3 8 npt m AP Recirculation Manifold Outlet AR Mix Manifold Inlet AW Primary Static Mixer Tubes AV Cleanup Static Mixer Tube AU Long Fasteners shipped loose with Remote Manifold kit MC Remote Manifold Carriage AV WL D Key AI Main Air Inle...

Page 19: ...ent Pump BB Siphon Tube BE Solvent Prime Valve BF Solvent Supply Hose BG Solvent Prime Hose BH Solvent Pump Wet Cup Key DA Solvent Air Shutoff Valve Relieving DB Solvent Air Pressure Regulator DC Solvent Air Pressure Gauge DD Solvent Air Outlet DE Solvent Air Inlet WL D DB DE DC DA DD ...

Page 20: ...ator EE Feed Pump EF Y Strainer EG Recirculation Tube EH Material Drain EJ Heating Fluid Drain Valve EK Heating Fluid Fill Port EL Heating Fluid Vent EM Air Valve Feed Pump EN Air Regulator Feed Pump EP Air Valve Agitator ER Air Regulator Agitator ES Y Strainer Valve ET Fill Port Cap EU Accessory Ports WL F 6 1 0 5 7 3 8 3 ...

Page 21: ...ain Air Shutoff Valve CF Controls the flow of inlet air Close main air shutoff valve to stop all components and pumps Fluid Line Components Recirculation Manifold AA Controls recirculation and pump priming Mix Manifold AB Combines A and B fluid into one fluid line Recirculation Handle AC Directs fluid flow for recirculation or mixing Move to open position to relieve fluid pressure prime pumps and ...

Page 22: ...tion heaters For approval rating see Approvals page 14 regarding your primary fluid heaters Hopper Heaters EC Immersion heaters used to heat the outer jacketed area of the double walled hoppers The outer jacket is filled with heating fluid to condition the resin and hardener materials Pumps XP hf Pump Assembly A mechanically linked fixed ratio system that consists of a singular air motor and two i...

Page 23: ...nd B materials are required for flushing Location 1 Locate the proportioner on a level surface Follow the Proper Lifting of Sprayer procedure 2 Position the proportioner for convenient operator access and maintenance proper routing of air and fluid lines and easy connection of components and accessories Proper Lifting of Sprayer Lift Using a Forklift The proportioner can be raised and moved using ...

Page 24: ... pails Follow your local code Use only metal pails which are conductive placed on a grounded surface Do not place pail on a non conductive surface such as paper or cardboard which interrupts grounding continuity To maintain grounding continuity when flushing or relieving pressure Hold the metal part of the spray gun firmly to the side of a grounded metal pail then trigger the gun Work area Ground ...

Page 25: ...llow local codes and regulations for sealing the power cable entering into the enclosure 7 Install the supplied terminal jumpers in the positions shown in the XPs hf Wiring Diagram page 26 8 Verify that all items are connected properly as shown in the XPs hf Wiring Diagram page 26 then close the electrical enclosure ZC door Power Cord Guidelines Use the guidelines listed in the table below to dete...

Page 26: ...T3 4T2 2T1 L1 L3 N TB 13 TB 14 TB 15 TB 12 TB 11 L2 8T4 5L3 3L2 1L1 7L4 6T3 4T2 2T1 L1 L3 L2 5L3 3L2 1L1 6T3 4T2 2T1 L1 L3 PJ ti37278a 230 Vac 1 Phase Delta NON HAZARDOUS LOCATIONS 230 Vac 3 Phase Delta 380 Vac 3 Phase Wye 480 Vac 3 Phase Delta WL D Disconnect Terminal Jumpers Disconnect Terminal Jumpers G MP G ZH HAZARDOUS LOCATIONS Disconnect Terminal Jumpers ...

Page 27: ...nted for your volume mix ratio See the Models chart on page 10 2 Verify that the motor position is adjusted correctly for that volume mix ratio If not perform the following Change Motor Position procedure Change Motor Position There are specific motor positions for each mix ratio setting To Adjust the position of the air motor 1 Verify that the XP hf motor air valve CA is closed 2 Perform the Chec...

Page 28: ...ods P 5 Slide the tie rods P and motor E until the indicator lines are aligned with your ratio 6 Tighten the three nuts 7 Install the pump guards Air Motor shown WL D 9 9 1876 3 NOTICE Do not hit the tie rods P with a hammer Damage to the air motor base may result ...

Page 29: ... Hose to Proportioner 1 Disconnect the solvent outlet hose BF and elbow fitting BK from the solvent flush valve AD 2 Loosen the union fittings AR on the mix manifold inlet that connect to the recirculation manifold AA to disconnect the mix manifold AB 3 For water jacketed heated hoses follow Connect Static Mixers Gun and Hoses page 30 4 For electric heated hoses see your heated hose manual for ins...

Page 30: ...eat up time and prevention of algae build up regardless of ambient temperature Oil can be used but heat up time will increase and the hopper level needs to be lower to allow for thermal expansion 2 Remove fill port cap ET and pour heating fluid in the outer cavity through the fill port EK NOTICE To prevent creating a flare on the mixer tube do not use a union swivel end on the mix tube inlet 8 WL ...

Page 31: ...NOTE If using water mix the maximum fluid level must be 1 in 2 5 cm below side port level NOTE If oil is the heating fluid the maximum oil level must be 3 in 7 6 cm below the hopper side port level 4 Replace the fill port cap ET WL E Maximum fill level NOTICE Any portion of the heating element exposed to air will lead to overheating and premature burnout Ensure that the element is completely subme...

Page 32: ...il 202659 do not fill past the maximum level shown in the oil fill sight glass Set the lubricator feed rate at one drop of oil per minute Do not overfeed the oil or the exhaust air may become contaminated Feed Pumps EE Fill the wet cup half full with Graco Throat Seal TSL or a compatible solvent WL E ti34269a Oil Fill Sight Glass Fill Port Adjusting Knob WL D ...

Page 33: ...Hoses Water jacket heated hose packages only 1 Add a 50 50 mixture of water and ethylene glycol to the reservoir ZF of the diaphragm pump ZG 2 Slowly open the needle valve ZP to circulate the fluid with the diaphragm pump ZG to remove air from the system 3 Continue adding heating fluid to the reservoir ZF as air continues to bleed from the system 4 Stop the pump when there is no more air in the sy...

Page 34: ...oughly agitated homogeneous and pourable prior to adding them to the hopper Stir hardeners back into suspension prior to adding material to the hopper 2 Move the recirculation lines U to grounded empty containers 3 Fill the A and B hoppers J with respective material up to 25 gallons Fill the A side blue with resin or base material Fill the B side green with the hardener or catalyst 4 Open the main...

Page 35: ...ate on page 36 9 Dispense fluid into the containers until clean fluid flows through the A and B recirculation lines 10 Close the feed pump air regulator EN 11 Close the feed pump air valve EM 12 Move the recirculation lines U back to the correct hopper 13 Repeat for the other side 14 If running solvent through the system for the first time proceed to Flushing on page 44 to empty the system of solv...

Page 36: ...he feed pump air valve EM to the OPEN position 6 Slowly open the feed pump air regulator EN until the pump starts Cycle the feed pump slowly until the feed pump stalls 7 Repeat steps 3 6 for the other heated hopper 8 Open the recirculation valve handle AC 9 Fully open the XP hf air pressure regulator CB then turn the air valve CA to OPEN Use the XP hf air pressure regulator CB to slowly increase t...

Page 37: ...ature The setting at the heater output thermometer should be approximately 10 F 6 C higher than the desired paint temperature Never exceed the XP system 160 F 71 C maximum fluid temperature rating See your Viscon HP heater manual for instructions As a general guideline heater knob settings are 7 for 105 F 40 C 8 for 135 F 57 C and 8 1 2 for 150 F 65 C NOTE If the hose heat is not being used for mo...

Page 38: ...to the pail Close the solvent prime valve BE and air valve DA 5 Open the solvent flush valve AD on the mix manifold 6 Ensure the trigger lock TL is engaged Remove the spray tip 7 Disengage the trigger lock TL and trigger the gun into a grounded metal pail while holding the metal part of the gun firmly against the side of the pail Use a pail lid with a hole to dispense through Seal around the hole ...

Page 39: ...he gun until all air is purged 9 Close the solvent pump air valve DA and trigger the gun to relieve pressure Engage the trigger lock TL Replace the spray tip 10 Close the solvent flush valve AD NOTE Solvent pump may stay pressurized while spraying WL D NOTICE To prevent material from curing inside the system never spray mixed material without the solvent pump and hose primed with solvent for prope...

Page 40: ...r lock TL Remove the spray tip 6 Slowly increase the XP hf motor air regulator CB enough to cycle the pumps 7 Disengage the trigger lock TL and trigger the gun into a grounded metal pail while holding the metal part of the gun firmly against the side of the pail Use a pail lid with a hole to dispense through Seal around the hole and gun with a rag to prevent splash back Keep fingers away from the ...

Page 41: ...e AE 4 Slowly increase the XP hf air regulator CB to cycle the pumps 5 Engage the trigger lock TL Remove the spray tip 6 Disengage the trigger lock TL and trigger the gun while holding against a grounded metal pail Use a metal pail lid with a hole to dispense through to avoid splashing back Dispense out of the mix hose until a well mixed coating flows from the gun 7 Engage the trigger lock TL inst...

Page 42: ...rial potlife or working time decreases with increased temperature Pot life in the hose is much shorter than the dry time of the coating Adjust the Restrictor The B side restrictor AJ reduces momentary lead lag ratio imbalance of the A and B flow into the static mixer tubes AN AW when the gun opens The error is caused by differences in viscosity volume and hose expansion The restrictor is used prim...

Page 43: ...ve the spray tip 4 Close the dual shutoff handle AE 5 Open the recirculation handle AC to relieve A and B fluid pressure 6 Close both feed pump air valves EM 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...

Page 44: ... valve AD 4 Disengage the trigger lock TL hold the gun against a grounded metal pail and trigger the gun into the pail Use a pail lid with a hole to dispense through Seal around the hole and gun with a rag to prevent splash back Be careful to keep fingers away from the front of the gun Continue flushing until clean solvent dispenses 5 Close the solvent pump air valve DA 6 Hold a metal part of the ...

Page 45: ...ing 3 Engage the trigger lock TL 4 Turn the XP hf motor air pressure regulator CB fully counter clockwise to shut off 5 Open the recirculation handle AC 6 Move the recirculation lines U to separate grounded fluid containers and pump remaining spray material out of the system 7 Open the feed pump air valve EM and pump material out of the hopper WL D ZB ZE ZN MP TI1949a TL WL D CB WL D B A AC WL E U...

Page 46: ...y material 10 Close the material drain EH and fill the hopper with solvent 11 Return the recirculation lines U to their respective hoppers 12 Open on the agitator air valve EP and pump air valve EM Circulate for two to three minutes 13 Repeat steps 4 10 Change the flushing solvent until it runs clean To flush the remainder of the system follow Flush Material Lines Procedure on page 47 WL D EM EP W...

Page 47: ...e the motor air shutoff valve CA 7 Lift to close the dual shutoff handle AE 8 Close the main inlet air shutoff valve CF 9 Remove the filters of the XP displacement pumps and soak in solvent Clean and replace the filter cap Always replace the filter o rings See your Xtreme lower pump manual 10 Fill the pump packing nuts of the XP displacement pumps with TSL NOTE Always keep the A side and B side so...

Page 48: ...of the stroke close the XP hf motor air valve CA and turn the air regulator CB 5 Turn off all heater switches ZB ZE ZN and the main power switch MP 6 Close the feed pump air valve EM when the feed pump is at the bottom of the stroke 7 Close the agitator air valve EP 8 Turn off main air shutoff valve CF WL D B A CB AC WL D CA CB NOTICE If fluid is allowed to dry on the exposed displacement rod dama...

Page 49: ... the time listed on the data sheet Spots that take longer to cure indicate insufficient pump loading leakage or lead lag errors at a remote mix manifold Appearance Test Spray material onto foil Look for variations in color gloss or texture that may indicate improperly catalyzed material Monitor Fluid Supply NOTE To prevent pumping air into the system which causes incorrect proportioning never allo...

Page 50: ...on page 48 Turn off all power 6 Clean the external surfaces only using a rag soaked in solvent that is compatible with the spray material and surfaces being cleaned 7 Allow enough time for the solvent to dry before using the system Change the Mix Ratio In order to change the mix ratio one or both pumps need to be replaced the air motor needs to be re positioned and the over pressure relief valves ...

Page 51: ...mponents 6 Ensure that the pipe plug PP is screwed into the strainer plug SP Install the strainer plug SP with the mesh screen MS and gasket SG in place and tighten Do not over tighten the strainer plug let the gasket make the seal 7 Open the Y strainer valve ES Ensure that there are no leaks and wipe the equipment clean Check Heating Fluid Level Gradual fluid evaporation can occur Check the level...

Page 52: ...4 41 N m Keep the wet cup half filled with Graco Throat Seal Liquid TSL Agitators After the first 100 hours or two weeks of operation change the gear reducer oil After that change the oil every 2500 hours or six months whichever comes first of operation under normal conditions More frequent oil changes are needed under severe operating conditions or in atmospheres containing excessive moisture or ...

Page 53: ...in output pressure drops on downstroke Dirty worn or damaged resin pump intake valve Clean repair pump see your Xtreme pump manual Pump operates but resin output pressure drops on both strokes Hardener output restriction Clean unplug hardener side Open manifold restrictor Fluid supply low Refill or change container Pump operates but hardener output pressure drops on upstroke Dirty worn or damaged ...

Page 54: ...er pressure relief valve 302 Pressure and flow surges on upstroke Feed pressure too high Every 1 psi of feed pressure adds 2 psi during upstroke Reduce feed pressure See Repair page 56 Fluid outlet pressure gauges split only at the top changeover if one gauge drops the other will rise Not fully loading one side on upstroke Increase feed pressure on side that dropped Increase feed hose size Clean i...

Page 55: ... individual components TROUBLE AREA Resin Pump Leakage 1 Throat packing 2 Piston packing 3 Piston ball check Resin Pump Falling Rising Hardener Pump Falling Falling Rising Rising TROUBLE AREA Hardener Pump Leakage 1 Throat packing 2 Piston packing 3 Piston ball check TROUBLE AREA Resin Pump Leakage 1 Throat packing 2 Intake ball check TROUBLE AREA Hardener Pump Leakage 1 Throat packing 2 Intake ba...

Page 56: ...rting on page 60 5 Use hoist to remove the pump assembly by the lift ring and carefully lift out of stand 1 Remove XP Displacement Pump 1 Flush all system components Follow the complete Flushing procedure starting on page 44 2 Disconnect the hopper fluid lines from the pump fluid inlet 228 3 Disconnects the outlet hose 12 or 24 For parts identification see Parts starting on page 60 4 Remove the sp...

Page 57: ... a hoist to remove the air motor by the lift ring 7 Refer to the air motor manual to service or repair the air motor Recirculation Manifold with Over Pressure Relief Valves 1 Flush all system components Follow the complete Flushing procedure starting on page 44 2 Disconnect all fluid hoses from the material recirculation manifold 35 3 Remove the mix manifold if it is assembled to the material reci...

Page 58: ... feel it fully lock against the valve seat Repeat for opposite side 7 Remove handle then place handle 711 on valve stem 302 at the vertical or near vertical position 8 Apply blue threadlock on the nut 704 threads and tighten the handle against the spring 720 and clip 718 Torque to 70 80 in lb 7 9 9 N m 9 Place the rod 712 and the second handle 711 on second valve stem aligned with the opposite han...

Page 59: ...ion Manifold Replacement Table Circulation Manifold 35 Part Relief Valve 302 Part Valve Sleeve Color Target Opening Pressure psi MPa bar Use with 262783 262809 Gold 7100 49 490 All XPs50 hf models 262806 262520 Silver 9250 64 638 All XPs70 hf models Colored Valve Sleeve ti19168a ti19169a ...

Page 60: ...ories voids the Hazardous Area Approvals La modificación de esta máquina o adición de accesorios no autorizados anula la zona peligrosa de idoneidad Modification de cette machine ou de l ajout d accessoires non approuvés par les vides de la zone dangereuse approbations 1 Apply anaerobic pipe sealant to all non swiveling pipe threads ...

Page 61: ...Parts 3A6283F 61 XP50s hf and XP70s hf Proportioners Continued WL F ...

Page 62: ...Parts 62 3A6283F XP50s hf and XP70s hf Proportioners Continued WL F 214 208 225 217 218 215 225 219 220 215 225 214 230 223 215 ...

Page 63: ...205447 COUPLING hose 1 52 16F537 HOSE air inlet solvent control 1 53 15B772 HOSE air solvent pump 1 54 061132 HOSE circulation solvent 1 55 16F359 LABEL warning fire exp hazard 1 56 VALVE safety see page 79 1 58 16F615 TOOL wrench Xtreme 1 59 111192 SCREW cap hex head 2 60 24F126 MODULE air controls solvent 1 61 262392 PUMP solvent see page 79 1 202 25N578 BASE painted XPs pallet 1 206 17V987 TUBE...

Page 64: ...Parts 64 3A6283F Water Jacketed Heated Hose Packages WL D 2 2 2 247 246 245 ...

Page 65: ...d head 4 4 C19075 SCREW cap hex head 4 4 63 111841 WASHER 4 4 203 26C482 HOPPER heated 240V 2 2 26C479 HOPPER heated 480V 2 2 204 17X398 HARNESS hopper 2 2 231 16P608 CLAMP mounting top heater 2 2 2 2 232 117535 SCREW cap socket head 4 4 4 4 233 121603 GRIP cord 2 2 234 126896 FITTING elbow 1 1 1 1 235 126898 FITTING elbow 1 1 1 1 236 126900 FITTING elbow 1 1 1 1 237 17D306 FITTING coupler 1 1 1 1...

Page 66: ...Parts 66 3A6283F Non Heated Hose Packages WL D 2 2 ...

Page 67: ...26C581 JUNCTION BOX 240V hazardous 1 26C582 JUNCTION BOX 480V non hazardous 1 26C583 JUNCTION BOX 480V hazardous 1 28 25C961 HEATER hf 240V non hazardous 2 25C962 HEATER hf 240V hazardous 2 26C471 HEATER hf 480V non hazardous 2 26C476 HEATER hf 480V hazardous 2 33 166590 FITTING bushing adapter 2 2 34 185065 ADAPTER cable 4 4 38 110963 SCREW cap flanged head 4 4 C19075 SCREW cap hex head 4 4 63 11...

Page 68: ...Parts 68 3A6283F Non Hazardous Location Electric Heated Hose Packages WL D 480V 240V ...

Page 69: ...Parts 3A6283F 69 Hazardous Location Electric Heated Hose Packages WL D 9 9 ...

Page 70: ... 26C476 HEATER hf 480V hazardous 2 33 166590 FITTING bushing adapter 2 2 34 185065 ADAPTER cable 5 4 38 110963 SCREW cap flanged head 4 4 C19075 SCREW cap hex head 4 8 63 111841 WASHER 4 4 64 18C158 SPLICE BOX 1 18B948 SPLICE BOX explosion proof 2 2 65 115942 NUT 3 112958 NUT 4 4 66 18C151 COVER splice box 1 19B335 BRACKET splice box 1 67 19Y807 BUSHING strain relief 1 1 68 19B130 CORD cable 1 1 6...

Page 71: ...lug 2 309 17N486 FITTING elbow 1 in npt 2 310 17N462 FILTER air 1 in npt 1 311 113163 VALVE ball vented 1 1 312 127784 COUPLING universal 1 in nptm 1 313 127785 COUPLING universal 1 in nptf 1 314 16W586 CABLE lanyard whip check 1 315 113161 SCREW flange hex hd 2 316 16P338 SCREW mach serrated hex head 4 317 17X550 BRACKET XPs filter mount painted 1 318 17X551 BRACKET XPs filter painted 1 319 11452...

Page 72: ... 113163 VALVE ball vented 1 0 1 404 17S719 FITTING 1 in npt x 3 in nipple 1 405 17N463 REGULATOR air 1 in npt 1 406 108638 FITTING pipe tee 1 407 100960 GAUGE press air 1 408 116648 FITTING swivel 1 in m x f 1 409 16P338 SCREW mach serrated hex head 4 410 17X553 BRACKET XPs regulator painted 1 Ref Part Description Qty ...

Page 73: ...5 FITTING swivel elbow 1 507 100081 BUSHING pipe 1 508 157350 ADAPTER 1 510 15M662 ROD tie 3 511 16U431 ADAPTER 50 cc pump lower not shown 1 512 15U606 NUT lock m16 x 2 3 513 LW050A LOWER assy 50 cc 1 514 15T337 RESERVOIR tsl 50 cc lwr 7 1 2 motor not shown 2 515 184128 COLLAR coupling 1 516 15T311 NUT coupler 1 517 277743 SHIELD 6 0 7 5 in 1 518 15V028 SHIELD drip 1 528 156589 FITTING union adapt...

Page 74: ...ULATOR air 3 8 npt 1 554 16F810 NUT regulator steel 1 555 114362 VALVE ball air 1 556 15T498 FITTING 90 swvl 5 32 t x 1 8 fnpt 1 558 113498 VALVE safety 110 psi 1 559 15T937 FITTING elbow swivel 1 4 npt x 5 32 t 1 560 155699 FITTING elbow street 2 561 164672 ADAPTER 2 563 054753 TUBE nylon rd black 0 75 568 108296 SCREW mach hex wash hd 4 569 109544 FITTING elbow pipe male 1 ...

Page 75: ...2 16T294 PLATE heater transfer PFP 2k 1 603 110837 SCREW flange hex 2 604 110996 NUT hex flange head 2 605 126692 FITTING tube NPT x tube 2 606 100721 PLUG pipe 2 608 189285 LABEL safety burn 1 609 120736 SCREW hex flange HD 2 610 126894 FITTING union 1 2 tube x 1 2 tube 2 611 054960 TUBE red nylon 0 375 9 5 mm ID 1 5 ft 1 612 054961 TUBE blue nylon 0 375 9 5 mm ID 1 5 ft 1 Supplied loose not inst...

Page 76: ...m 2 3 4 5 6 701 713 716 711 702 717 708 707 705 710 712 713 703 709 708 708 709 717 705 2 3 r_258988_3a0420a_1c 718 718 702 2 3 4 4 704 720 720 711 704 3 3 6 5 5 6 Ref Part Description Qty 701 16D693 BLOCK manifold recirculation 1 702 262520 VALVE over pressure relief silver XP70s hf 2 262809 VALVE over pressure relief gold XP50s hf 2 703 156684 UNION 1 2 in male x female 2 704 112309 NUT hex jam ...

Page 77: ...108126 FITTING tee street 1 802 126897 FITTING elbow 1 2 tube x 1 4 nptm 2 803 126898 FITTING elbow 1 2 tube x 1 2 nptm 1 804 126899 FITTING 1 2 tube x 1 2 nptm 1 805 16D939 FITTING nipple reducing 1 806 16R871 BOTTLE overflow 1 2 npt 1 807 17P088 BRACKET XP hf re circ painted 1 808 206264 VALVE needle 1 809 24T761 PUMP acetal w pvdf check husky 1 810 113161 SCREW flange hex hd 2 811 17N910 TUBE r...

Page 78: ...readlock to top thread only Pins and lanyards must be positioned toward the outside of the pump as shown Allow ends of lanyard to hang freely Remove ground screw and washer from the motor then use to install ground wire 2 3 4 5 6 Torque together to 230 250 ft lb 312 339 N m Torque together to 95 105 ft lb 129 142 N m 12 13 WL E F E D D G E ...

Page 79: ...124665 NUT captive 10 32 4 922d 15T468 LABEL warning 2 930 124078 CLAMP spring constant tension 2 931 15H108 LABEL safety warning pinch 1 932 111192 SCREW cap flange hd 2 934 184130 BRACKET ratio indicator 1 935 16E882 STRAP lowers 2 940 244525 WIRE grounding assembly 1 Replacement safety labels tags and cards are available at no cost Ref Part Description Qty Ref Description 57710x 57720x 57730x 5...

Page 80: ...rculation Overpressure Valve see page 59 XP50 hf 262809 gold XP70 hf 262520 silver 15K692 Seal Mix Manifold Check Valve Cartridge NOTE 15K692 must be replaced when cleaning the check valves 1 2 in Mix Manifold Inlet Ball Valves 24M601 Ball valve repair kit 262740 Spare valve no handle 262739 Spare valve single handle 248927 Spare Mix Elements pack of 25 1 2 in OD x 12 element acetal plastic 248837...

Page 81: ...ounting carriage with a heater block to circulate water jacketed hose heat to maintain heat on the mix manifold Remote Mix Manifold Carriage 262522 A protective guard to mount mix manifold remote See mix manifold manual 3A0590 for more information Mix Manifold Restrictor Wrench 126786 Gun Splitter with Carriage 262826 One splitter valve to use one two or three spray guns with the system Provides i...

Page 82: ...Dimensions 82 3A6283F Dimensions System Dimensions WL D LQ FP LQ FP LQ FP Top View Side View ...

Page 83: ...rainer 20 mesh XP Pump Outlets 30 mesh XTR Spray Gun 60 mesh Viscosity Gravity Feed 200 20 000 cps pourable Pressure Feed Any viscosity that will not require feed pressure more than 15 of outlet pressure Temperature Operating 40 130 F 4 54 C Storage 30 160 F 1 71 C Maximum Fluid Temperature 160 F 71 C Wetted Materials Housings and Manifold Carbon steel with electroless nickel plating Displacement ...

Page 84: ...r Motor manual for sound data Air consumption per 1 gpm 3 78 lpm of flow XPs70 hf 75 cfm at 100 psi 2 12 m3 min at 6 7 bar 0 67 MPa XPs50 hf 60 cfm at 100 psi 1 7 m3 min at 6 7 bar 0 67 MPa Double Wall Hopper U S Metric Temperature set point 110 F 43 C Spray material capacity 25 gallons 94 6 liters Heating fluid capacity 12 gallons 53 liters Feed Pump U S Metric Input Maximum air input 100 psi 6 7...

Page 85: ...7 bar 0 67 MPa 60 cfm 1 70 m3 min Speed Maximum shaft speed 60 rpm Gear ratio 20 1 Torque Stall torque at maximum pressure 1120 in lb 127 N m Sound Data See XD Agitator manual for sound data Solvent Pump U S Metric Input Air pressure 10 100 psi 0 67 MPa 6 7 bar Air inlet size 1 2 in npt f Output Maximum working pressure 4500 psi 3 1 MPa 31 bar Fluid outlet size 3 8 in npt Flow at maximum pump spee...

Page 86: ...n 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 warr...

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