Graco 3A0420T manual

Instructions-Parts XP Proportioners Mechanically linked fixed ratio pl ural-component system used for proportioning, mixing, and spraying two component coatings. For professional use only. See pag e 11 for max imum worki ng pressure and mod el inform ation. Important Safety Instructions Read a ll warnings and instruct ions in t his manu al. Save th[...]

2 3A0420T Contents Related Manua ls . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Important Two-Compone nt Material Information . 7 Isocyan ate Condition s . . . . . . . . . . . . . . . . . . . . . 7 Material S elf-igniti on . . . . . . . . . . . . . . . . . . . [...]

Relate d Manuals 3A042 0T 3 Related Ma nuals Manuals are a vailable at www.g raco.com. Compo nent manuals in Engli sh: Manual Description 312145 XT R ™ 5 and XT R ™ 7 Spray G uns Instru ctions -Parts Pump Pac kage Componen ts 307158 Vi scount ® II Hydr aulic Motor Ins truc- tions -Parts 311238 NXT ® Ai r Moto r I nstru ction s-P arts 311762 X[...]

Warnings 4 3A0420T Warnings The foll owing warni ngs are for the setup , use, gro unding, ma intenanc e, and rep air of this equipment . The ex clama- tion po int symbol alerts yo u to a ge neral warn ing and the hazard sy mbols r efer to pro cedure-s pecific r isks. Whe n these sy mbols a ppear in the body of this ma nual, re fer back to these Wa [...]

Warn ings 3A042 0T 5 SKIN INJECTION HAZARD High-pr essure flu id from gu n, hose leaks, o r ruptured component s will pi erce skin . This m ay look l ike just a cut, but it is a ser ious injur y that c an result in am putation. Get immediate surg ical treatmen t. • Do not spr ay without ti p guard a nd trigger gua rd insta lled. • Engage tr igg[...]

Warnings 6 3A0420T TOXIC FLUID OR FUMES HAZARD Toxic flu ids or fum es can ca use serious injury or death if spl ashed in th e eyes or on s kin, inha led, or swa l- lowed. • Read MSDS s to know the speci fic hazards of the flui ds you are using. • Store ha zardous fluid in approved c ontainers , and disp ose of it accordin g to appl icable g ui[...]

Importa nt Two-Component Material Information 3A042 0T 7 Important Two-Compon ent Material Infor mation Isocyanate Conditions Material Self-ignition Keep Compo nents A and B Separate Moisture Sensit ivity of Isocyanates Isocyana tes (ISO ) are ca talysts used i n two com ponent foam and poly urea coati ngs. ISO w ill react with mois ture (such as h[...]

Importan t Two-Com ponent Ma terial Info rmation 8 3A0420T Changing Mat erials • Changing m aterial types used in your system requires special attention to avoid equipment dam- age and do wntime. • Always clean the fluid in let stra iners af ter flushin g. • When cha nging betw een epoxi es and ureth anes o r polyureas , disasse mble and c le[...]

Overview 3A042 0T 9 Overview Usage The XP is a mec hanically linked fixed ra tio system that can m ix and spr ay most tw o-compo nent epox y and ure- thane p rotective coatings . When us ing quic k-setting material ( less than 1 0 minute po t life) a remote mix man- if old mu st be u sed or m ateri als m ust mix at t he gun. Quick set manif old 24M[...]

Initial Sys tem Setup 10 3A0420T Initial Sys tem Setup 1. Check t he shi pment fo r accura cy. Ensur e you have receiv ed everyth ing you o rdered. See Component Identificat ion , page 14. 2. Che ck for loose fittings a nd fastene rs. 3. Ins tall optiona l solvent fl ush pump kit 2623 93, if ordered. S ee manu al 310863 for instruct ions. 4. Mou nt[...]

Models 3A042 0T 11 Models Cart-Mounted System s NOTE: All cart-m ounted sy stems l isted are E x rated: See Ac cessories and Ki ts on page 55 for a list of all optional a ccesso ries. NOTE: The “Standar d” mix ma nifold s election means the mix mani fold is mou nted on the cart and comes wi th mix- ers, 25 ft of 3/8 in. mix hose, and 10 ft of 1[...]

Models 12 3A0420T XP50 with 6500 Air Motor 282000 --- --- Standard 35 ft (10.7 m) XTR5 --- --- --- 282101 282100 1.0:1 4500 (31, 310 ) 100 (0.7, 7) 45:1 282102 ✔ 282105 --- --- --- 282106 ✔ 282151 282150 1 .5:1 Standard 35 ft (10.7 m) XTR5 5000 ( 34, 344) 90 (0.62 , 6.2) 55:1 282152 ✔ 282155 --- --- --- 282156 ✔ 282201 282200 2 .0:1 Standar[...]

Models 3A042 0T 13 Bare Proportionin g Pump Packages Packag es incl ude motor, pum p lowe rs, and all connec- ti on hard war e. NOTE: All p ump package s are Ex rated e xcept for th e XP-h pump pack ages (284x xx): Hydrau lically powered pu mp packa ges (XP- h) are not avail able as co mplete s ystems. Re fer to m anual 307 158 for hy draulic ap pl[...]

Compone nt Identifica tion 14 3A0420T Component Ide ntifi cation Key: A Air Supply Hose for Moto r B Main Ai r Controls; s ee page 1 5 C Air I nlet - 3/4 nps m(f) D Hi gh Pressure Fl uid Pump EM o t o r F Fluid Heat er (o ptio nal) G Solvent Flu sh Pump (optional); see pa ge 16 H Solv ent Flush Pump Air Controls; see pa ge 16 J 7 Gall on Hoppers (o[...]

Compone nt Identifica tion 3A042 0T 15 Fluid Cont rol Asse mbly Main Air Controls F IG . 2 AC AA AF AE AD AB AM AL AK AJ AN Key: AA Fluid M anifold AB Mi x Manifo ld AC Circu lation Hand le AD Solvent Flush Valve AE Dual Shut off Handle AF F luid Press ure Gaug es AG Fluid Su pply I nlet (Behin d Fluid Mani fold) AH Fluid C irculati on Fitting s AJ[...]

Compone nt Identifica tion 16 3A0420T 45:1 Solvent Flush Pu mp Kit 262393 (o ptional) Pump Air Controls F IG . 4 Key: BA Solvent flus h pump (Merkur Pu mp) BB Fluid Inl et BD Muffler BE Prime/Flus h/Sample valve BF Fl uid Outlet Hos e BG Circulatio n hose BA BB (suc tion hose n ot shown) BD BG BF r_571100 _3a04 20a_4a-2 BE F IG . 5 Key: DA Solvent [...]

Compone nt Identifica tion 3A042 0T 17 Air Line • Bleed-type master air va lve (CA): Re quired in your s ystem to re lieve air trapped b etween it an d the air m otor when the valv e is closed. B e sure the valve i s easil y access ible fr om the pu mp and located d ownstrea m from the air regul ator. • Pump air regulator (CB): Contr ols pump s[...]

Setup 18 3A0420T Setup Location 1. Loc ate the prop ortioner on a level surface. 2. Po sition th e proportio ner for convenient operator access and main tenance, s afe routing of air an d fluid li nes, and e asy connec tion of comp onents and access ories. 3. For permane nt mounting , remove wheels a nd mount the fr ame to the floor. See Dimensions[...]

Setup 3A042 0T 19 Wire Systems wi th Explosion-Proof Heaters (Hazardous location syste ms only) Improperl y installe d or connec ted equipm ent will c reate a hazar dous conditi on and ca use fir e, explosio n, or electric shock. Follow loc al regulations . When exp losion-proo f heaters ar e used, ens ure the wir- ing, wiring c onnectio ns, switch[...]

Setup 20 3A0420T Motor Posi tion The motor p osition mus t be set fo r the volum e mix rati o of the sy stem. NOTE: Changing the motor posit ion does not change the mix r atio. Check Moto r Position 1. Ve rify that the corre ct pumps are mounted f or your mix rat io by vo lume. See chart i n Bare Proportion- ing Pump P ackages on page 13. 2. Ve rif[...]

Setup 3A042 0T 21 Connect Air Supply 1. Con nect the air sup ply hose to the 3/4 np t(f) air filter inlet (C). NOTE: Use a 3/4 in. (19.1 mm) ID minimu m air hose. Air consumption is 75 cfm per gallon per minute spraying. Do not use pin fitting type quick discon- nects. 2. Rem ove plugs a s necessary fo r solvent p ump and feed sup ply pump air ho s[...]

Pressure Relief P rocedure 22 3A0420T Pressure Rel ief Procedure Relieve A and B Fluid P ressure 1. En gage the tr igger loc k. 2. Cl ose th e main ai r shu toff va lve (C A). 3. Sh ut off heater s, if used. 4. Shu t off feed pum ps, if used . 5. Rem ove the spr ay tip and clean. 6. Dis engage th e trigger l ock. 7. Hol d a metal p art of the gun f[...]

Prime Empty System 3A042 0T 23 Prime Empt y System Prime A a nd B Fluids NOTE : The equip ment is te sted wit h min eral o il a t the facto ry. If nece ssary, flus h out the oil with a compatible solvent before spray ing. See Empt y and Flush Entire Sy stem (new system or end of job), page 29. Do not install the gun spray tip yet. To avoid splash- [...]

Prime Empty System 24 3A0420T Prime Solvent Flush Pump Follow instructio ns if the optional s olvent f lush pump k it is used . 1. Con nect the flush pa il ground wire to a metal pai l of solvent . 2. Pl ace the sip hon tube an d the solv ent circu lation hose (B G) in the p ail of so lvent. 3. O pen the solvent prim e valve (BE) on the solv ent pu[...]

Prime Empty System 3A042 0T 25 Recirculate Prior to Spraying o r Re-Prime After a Pum p Runs Dry NOTE: Agitat e, recirc ulate, and he at the mater ial only as n ecessary to avoid mix ing air into the fluid. Use the reci rculation mode when heat ing the mater ial is required. Note the temp erature at t he top of the heater (outgoin g or back t o the[...]

Spray 26 3A0420T Spray NOTE: After the first day of spra ying follow Pres- sure Relief Procedure, page 22, and tighte n the throat pac king nuts on both pumps. 1. If h eaters are used, turn th em on. To adj ust the heater te mperature, ref er to the V iscon HP m anual for inst ructions, and the Heat Fluid s ection, page 25. Circulate a s necessa ry[...]

B Side M ix Manif old Res triction 3A042 0T 27 B Side M ix Ma nifol d Restri ction The B sid e restrictor ( AJ) control s “lead/lag” ratio errors of the A an d B flo w into the s tatic mixe r tubes. These errors occ ur momentar ily when th e gun opens. T he error is caused by difference s in viscosity , volume, an d hose expans ion. The restr i[...]

Flush M ixed Ma terial 28 3A0420T Flush Mixed Mate rial Flush the m ix manifol d when any of the foll owing situa- tions occur. • breaks in sp raying • ov ernight shutdo wn • mixed ma terial in sy stem approa ching end of potl ife To flush th e entire system, see Empty and Flush Entire S ystem (new s ystem or en d of job) , page 29. Flush Mix[...]

Empty a nd Flush E ntire Syste m (new syste m or end o f job) 3A042 0T 29 Empty and Flus h Entire Syst em (new system or end of job) NOTE: • If the system in cludes heaters and heated ho se, turn them off and allow to cool before flushing. Do not turn on the heaters until the fluid lines are clea r of solven t. • Cover fluid conta iners and use[...]

Shutdown 30 3A0420T 7. Run the pumps until the A a nd B hoppe rs (J) are empty. Sa lvage the materia l in separa te, clean con- tainers. 8. Cl ose th e main ai r shu toff va lve (C A). 9. Wi pe the hop pers (J) c lean, then add solvent to each. Mov e the circul ation lines (U) to waste con- tainers and push out the dirty fluids. 10. Move the r ecir[...]

System Verificatio n 3A042 0T 31 System Verific ation Graco recomme nds run ning the fo llowing te sts d aily. Check fo r Normal O peration Every t ime yo u start sp rayin g: • Watch the fluid gau ges (AF). A pressure d rop occurs dur ing pump s troke chang eover. It sh ould be quick and s ynchrono us. • Stop the p umps on th e upstrok e. Check[...]

Maint enanc e 32 3A0420T Maintenanc e Hose Electrical R esistance Check el ectrical re sistance o f hose s regul arly. If total resist ance to grou nd excee ds 29 meg ohms, re place hose imm ediately. Filters Once a w eek check , clean, and rep lace (if ne eded) the foll owin g fil ters. • Both pump filters; s ee lower manual for i nstruction s. [...]

Troubles hooting 3A042 0T 33 Troubleshoot ing ✖ Fluid ratio will b e wrong. ◆ Purge all air from system befor e proportioning fluids. Problem Cau se Solu tion System stops or will not start. Air pre ssure or vol ume too l ow. Incre ase; check ai r compres sor. Closed or restric ted air line or air valve. Open o r clean . Fluid valves c losed. O[...]

Troub leshooti ng 34 3A0420T Pump T roubl eshoo ting This cha rt uses proportion ing fluid gauges to determin e pump mal function s. Obse rve the gaug e readin gs durin g the stroke direction indicate d by the bo ld arrow, a nd immedi ately afte r closing the gun or mix manifo ld. Ref er to other manuals to troubles hoot indiv idual comp onents. Fl[...]

Repair 3A042 0T 35 Repair Follow Shutdo wn proce dure on page 30, which include s flushi ng, if se rvice time may e xceed po t life time, b efore serv icing fluid c omponents , and befo re transpo rting sys tem to a se rvice area. Pump Assembly The displ acement p umps and a ir motor m ay be removed and servi ced separ ately or the entire p ump and[...]

Repair 36 3A0420T Remove Moto r 1. Sto p the pumps near th e bottom of t heir stroke. Fol- low Shutdown , page 30. 2. Dis connect the air line fr om the ai r motor (1 03). 3. Rem ove the air motor rod cov er (121) and pump guards (1 22). 4. Use a w rench to hold the tie r od (102) f lats to keep the rods from turning. Unscr ew the nuts (108) and wa[...]

Repair 3A042 0T 37 F IG . 10: Air C ontrol Asse mbly 258983 201 215 214 213 216 211 202 203 204 209 208 207 205 206 210 214 209 206 r_571101 _3A0420 A_1a-2 Air Flow Air Fl ow 5, 8[...]

Repair 38 3A0420T Mix Manifold Assem bly 1. Foll ow Pressu re Relief P rocedure , p age 22. 2. Dis connect the fluid hos e (25) and the flush hose from the m ix manifol d (36). 3. Loo sen the un ion fittin gs (306) t hat connect to the mix mani fold adap ter fittings . 4. Rem ove the mi x manifo ld assem bly (36). 5. Se e mix man ifold man ual for [...]

Repair 3A042 0T 39 7. Sl ide handl e (311) ont o valve ste m and rot ate approxi mately 90° u ntil you feel it ful ly lock agai nst the va lve seat. Rep eat for op posite s ide. 8. Rem ove handle th en place handle (311 ) on valve stem (302) at the vertical, or near ve rtical, posit ion. 9. Ap ply blue threadlo ck on the nut (304) t hreads a nd ti[...]

Repair 40 3A0420T Hoppers 1. If m aterial is in the hop per pump out the re maining material. 2. If th e pump has failed: a. Pl ace a waste c ontainer be neath the p lug on fit- ting (61 ). Remove the plug. b. Drain all mate rial from h opper in to the waste conta iner. c. Install p lug after material i s no longer draining from fitting ( 61) . 3. [...]

Repair 3A042 0T 41 Optional F luid Heaters NOTE: Wiring for heaters is not prov ided. See the Vis- con HP he ater manu al for wiri ng, repair, an d parts i nfor- mation for explosio n-proof hea ters. Service and Re pair 1. Foll ow Pressu re Relief P rocedure , p age 22. 2. Dis connect the fluid li nes and e lectrical wi ring from the fluid heater. [...]

Parts 42 3A0420T Parts Cart-Mounted System 1 15 14 13 16 11 3 17 18 9 8 7 5 10 12 17 64 50 53 38 54 13 13 11 52 1. Apply anaerobic pipe sealant to al l non-swiveling pipe threads. 2 r_5711 01_3a042 0a_30 a r_5711 01_3a042 0a_30 a[...]

Parts 3A042 0T 43 Cart-Mounted System Contin ued 23 22 4 18 5 6 24 55 56 58 59 60 61 62 24 24 22 41 37 35 36 32 27, 28 26 52 48 18 5 1 57 69 49 “A ” 49 “B” 51 70 27, 28 32 27, 28 25 29 30 31 r_571101 _3a04 20a_44a- 1 r_571101 _3a04 20a_45a TI17434 a 90 89 65 (i nside hopp er) Standar d Mix Man ifold Model s 66[...]

Parts 44 3A0420T Cart-Mounted System Contin ued 31 30 36 35 Quickse t Mix M anifol d Mode ls TI19233 a[...]

Parts 3A042 0T 45 Parts Commo n to All Sy stems ▲ Replacem ent Danger and Warnin g labels , tags, and cards are avai lable at no cost. Ref Part Description Qty 1 258 913 CART, we ldment 1 2 262 476 AXLE 1 3 111 841 WASHE R, plain 5 /8 2 6 100 101 SCREW, ca p, hex head 4 7 113 362 WHE EL, semi-p neumatic 2 8 154 628 WASHER 2 9 113 436 RING, r etai[...]

Parts 46 3A0420T Parts V arying By M odel - XP3 5 Systems ▲ Replacem ent Danger and Warnin g labels , tags, and cards are avai lable at no cost. Ref Part De scription Quantity (By System) 262804 281000 281101 281102 281105 281106 281201 281202 281205 281206 281252 281255 281256 281301 281302 281305 281306 281401 281402 281405 281406 4 281100 PU M[...]

Parts 3A042 0T 47 Parts V arying By Model - 282xx x (XP50 ) System s ▲ Replacem ent Danger and Warnin g labels , tags, and cards are avai lable at no cost. Ref Part Description Qua ntity (B y Syst em) 282000 282101 282102 282105 282106 282151 282152 282155 282156 282201 282202 282205 282206 282251 282252 282255 282256 282301 282302 282305 282306 [...]

Parts 48 3A0420T Parts V arying By M odel - 28 3xxx (XP50 Quicks et) System s ▲ Replacem ent Danger and Warnin g labels , tags, and cards are avai lable at no cost. Ref Part Description Quantity (By System) 283101 283102 283201 283202 283301 283302 283401 283402 4 282100 PUM P PACKA GE, fixed rat io, 1.0:1 1 1 282200 PUM P PACKA GE, fixed rat io,[...]

Parts 3A042 0T 49 Parts V arying By Model - XP7 0 Systems ▲ Replacem ent Danger and Warnin g labels , tags, and cards are avai lable at no cost. Ref Part Descrip tion Quantity (By Syste m) 571000 571101 571102 571151 571152 571201 571202 571251 571252 571301 571302 571401 571402 4 571100 PUM P PACKAG E, fixed ra tio, 1.0:1 1 1 571150 PUM P PACKAG[...]

Parts 50 3A0420T Bare Proportionin g Pump Package 1 Torque together to 50- 60 ft -lb (68-81 N•m). Torque to 145-15 5 ft -lb (196-210 N •m). Apply blue thread sealant. Insert lanyard from locking pin ont o pumps (17, 18) as shown. Do not apply lubricant. Torque to 70-80 ft -lb (95-108 N •m). Apply lithium grease to mating tapered surfaces. 1 2[...]

Parts 3A042 0T 51 Parts Commo n to All Pump Packages ▲ Replac ement D anger an d Warnin g labels, tags, and c ards are a vailable a t no cost. ❄ Kit NX T102 (d e-ic e kno b 5-pack ) als o avai lable . Parts Vary ing by Pump Package ▲ Repl ace ment Da nger an d War ning labels , tag s, an d card s are a vaila ble a t no cost. ❖ Includes rupt[...]

Parts 52 3A0420T Air Controls, 258983 ✖ Not show n. 1. Apply anaerobic pipe sealant to all non-swiveling pipe threads. Connect hose (214) to fitti ng (206) and air distribution manifold (213). 2 201 215 214 213 216 211 202 203 204 209 208 207 205 206 210 214 209 206 r_571100 _3A0420 A_1a-1 Air Flow Air Flow 211 TI17433a 2 Ref. No. Part No. Descri[...]

Parts 3A042 0T 53 Fluid Circulatio n Manifold with Over Pressure Relief Valve Assembly 2 62784 (XP3 5); 2627 83 (XP50); 262806 (XP7 0) ✖ Not show n. Ship ped loos e. ★ For XP 35 systems only. ◆ For XP 50 systems only. † For XP 70 systems only. NOTE: Loose fittings are supplied with replacement manifold to also fit Ser ies A XP Proportion er[...]

Recomm ended Spare Parts 54 3A0420T Recommended Spar e Parts Keep thes e spare parts on han d to redu ce downtim e. Pump Repair Kits See page 13 to see wh at pump s are used on your sy s- tem. Se e lower manu al for repa ir kits. Pump Filter O-rings (packs of 10) 262483, T op o-ring 244895, Mi ddle o-ring 262484, Bo ttom o-r ing Recirc ulation/Over[...]

Acce ssories and Kits 3A042 0T 55 Accessories and Kit s Acceptable F or Use in Explosive Atmospheres Blue 7 Gallon Hopper Kit, 2 4F376 Green 7 Ga llon Hopper Kit, 24F37 7 Mount to the sides o f the XP sy stem. See manual 406860 for more i nformation. Solve nt Pump Kit, 2 62393 For suppl ying solv ent to the m ix mani fold. See m anual 310863 for mo[...]

Access ories and Kits 56 3A0420T Not Approved For Explos ive Atmospheres These ki ts do not c arry the EX mark. 2:1 Fe ed Pu mp Kit , 2562 75 For su pplying vi scous mat erials fr om a drum to X P sys - tem. Se e manual 312769 for more in formation. 2:1 Drum Feed Kit, 256232 One T2 pum p feed ki t and one T wistork agita tor kit for mixing a nd sup[...]

Technica l Data 3A042 0T 57 Technical Da ta XP Proportioner s U.S. Metric Maximum Fluid W orking Pressure See Models section beginning on page 11. Maximum Air/ Hydraulic Oil Working Pr essure See Models section beginning on page 11. Combined Fluid Output (cc/cy cle) See Models section beginning on page 11. Pressure Ratio See Models section beginnin[...]

Dime nsions 58 3A0420T Dimensions Weigh t: Full XP35, XP50, or XP70 S ystem with heaters, solvent flush pump, and hoppers 575 lb 261 kg Bare XP35, XP50, or XP 70 system with no heaters, solvent flush pump, or hoppers 425 lb 193 kg XP35, XP50, or XP70 Pump only 286 lb 130 kg XP-h System 290 lb 132 kg 32 in. (813 mm ) 52 in . (1321 mm ) 60 in . (1524[...]

Dimen sio ns 3A042 0T 59 6.75 in. (171.45 m m) 16.90 in. (429 .26 m m) 40 in . (1016 mm ) 15.25 in. (387.35 mm) 22 in . (558.8 m m) 32 in. (812.8 mm) Floor Moun ting Dimensio ns, Top View[...]

Dime nsions 60 3A0420T Bare Proportioner Mo unting Hole Dimen sions The dim ensions bel ow is the mi nimum ope ning size f or mounti ng a bare proportion er. 7.5 in . (190.5 m m) 3.75 i n. (95.25 m m) 5.06 in. (128.52 m m) 10.3 75 in. (263.525 mm) 3/8-16 (4x ) 10.125 in. (257.175 mm) 14.35 in. (364.49 m m) 9.25 in. (234.95 m m) 0.25 in. (6.35 mm) 1[...]

Dimen sio ns 3A042 0T 61 Wall Mount Bracket 26 2812 Dimensions 15.0 in. (381 m m) ti190 46a 17.9 in. (455 mm) 18.4 in. (467 mm) 11.8 in . (300 mm ) 9.75 in. (248 m m)[...]

Dime nsions 62 3A0420T Floor Stand 24M2 81 Dimensions Hydraulic Unit Dim ensions ti1904 7a 21.2 in . (538 mm ) 30.3 in. (770 mm) 17.8 in. (451 mm) 32.7 in . (829 mm ) ti1904 8a 53 in. (1346 m m) 30.3 in. (770 mm) 17.8 in. (451 mm) Shown ins talled o n floor stan d[...]

Dimen sio ns 3A042 0T 63[...]

All written and v isual data contained in this document r eflects the lat est product information available at the ti me of publica tion. Graco reserves the right to make changes at any time without notice. For patent information, see www.graco.com/patents. This manual contains E nglish. MM 3A0420 Graco Hea dquarters: M inneapo lis Internati onal O[...]