Page 2 - Contents
2 3A2989G Contents Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Keep Components A and B Separate . . . . . . . . 6 Chan...
Page 3 - Models
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 Fl...
Page 4 - Warnings; WARNING
Warnings 4 3A2989G 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 manua...
Page 6 - Changing Materials; Component Identification; Never
Component Identification 6 3A2989G 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 harde...
Page 7 - Pressure Relief Procedure; Park Fluid Pump Rods; Appendix A - User Interface Display
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 ha...
Page 8 - Flush Mixed Material; Troubleshooting
Troubleshooting 8 3A2989G 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...
Page 9 - Repair; Replace Air Filter Element; Both Filters; Main Air Inlet Manifold Filter; Air
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...
Page 10 - User Interface/Control Box; Replace Single Solenoid Module; Remove Shroud and Front Panel of Control Box
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); ...
Page 11 - Update USB Module Software; Replace USB Module
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 tok...
Page 12 - Replace Alarm
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 ve...
Page 13 - Display; Upgrade Software
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 ve...
Page 15 - Junction Box
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 ...
Page 16 - Update Fluid Control Module Cube
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 fac...
Page 17 - Air Controls
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 m...
Page 18 - System
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 ...
Page 19 - Dosing Valve Assembly; Ratio Control Valve Assemblies; Ratio Control Valve Assem-
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. D...
Page 20 - Sensors; Replace Fluid Pressure Sensor
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 Ra...
Page 21 - Remove Pump Assembly; Remove Displacement Pump
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 inl...
Page 22 - Remove Air Motor; Solvent Pump
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...
Page 23 - Heaters; Related Manuals; Service and Repair; Replace
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 serv...
Page 24 - Replace Radar Level Sensor; Feed; Set Up a New Guided Level Sensor
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 ...
Page 25 - Set Up a New Guided Radar Level Sensor
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 h...
Page 27 - Electrical Schematics; Simplified Electrical Schematic
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-...
Page 28 - Power
Electrical Schematics 28 3A2989G Page 2 of 3 H OS E H E A TE R 4K W 245869 262853 16T525 16T525 16T859 A F LU ID H E A TE R 5 .4 KW NEMA L6-20R 3 1 2 4 3 1 2 4 GND-2 GND-2 GND-2 BT AN K H E A TE R 1 .75 K W F LU S H H E A TE R 5K W A T A N K H E A TE R 1 .75 K W NEMA L6-30R NEMA L6-20R NEMA L6-20P N...
Page 29 - bu
Electrical Schematics 3A2989G 29 Page 3 of 3 1264 9 5 12427 3 1264 9 4 1264 9 4 127172 24T052 24T052 127172 121 8 06 121 8 06 A L EV E L S E N S OR 16T12 3 FCM1 B as e - 2 89 6 9 7 FCM - 2 89 6 9 6 1 5 7 2 B L E V E L S E N S OR FC M 1 1264 9 6 16T072 F C M 1 CAN U S B1 B as e - 2 89899 U S B - 2 89...
Page 30 - XM PFP Air Logic Schematic; PLFURQ
Electrical Schematics 30 3A2989G XM PFP Air Logic Schematic 1” {ರ PLFURQ $872 -XQFWLRQ %R[ 6ROHQRLGV ;0&RQWURO %R[ 6ROHQRLGV 7R3QHXPDWLF 5DPSXPSSLORW$ 7R3QHXPDWLF 5DPSXPSSLORW% 'RVLQJ 9DOYHV ;0'XDO SLORW YDOYH 3803 $ 3803 % +LJK3UHVVXUH 0HWHULQJ3XPSV SVLOLPLW (;+ 3XPS 5HJ 0LFURQ )LOWHU5HJ 0DLQ ...
Page 31 - Feed Module Air Controls Schematic
Electrical Schematics 3A2989G 31 Feed Module Air Controls Schematic 3XPS 3LORW :DWHU 3XPS 7DQN +HDW 6SHHG &RQWURO ~ 7XEH 212)) &LUF$JLWDWRU ~ 5HGKRVH 212)) 7DQN 3UHVVXUH 5HG KRVH ~ ~ 5HGKRVH 9HQW 3UHV 5HOLHI 9DOYH 7DQN/LG 0DQLIROG $JLWDWRU 0RWRU /XEULFDWRU $LU)URP 3URSRUWLRQHU ೀ5HGKRVH ~ 5H...
Page 32 - Parts; Description
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 26286924W628 Mo...
Page 43 - Heated Hose Bundle
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,...
Page 48 - Part
Parts 48 3A2989G ▲ Replacement Danger and Warning labels, tags, and cards are available at no cost. --- Not for sale. ❄ Not shown. z Base electronic components do not have XM PFP-specific software installed. Therefore, use software upgrade token (506) to install software before use. † Includes softw...
Page 49 - Ref
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,...
Page 53 - Tank Air Manifold Assembly
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 1006 1007 1003 1010 1012 1011 1013 1009 1008 Ref Part Description Qty 1001 189016 MANIFOLD, air, inlet 1 1002 15566...
Page 58 - Technical Data; XM PFP
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 h...
Page 60 - Dimensions
Technical Data 60 3A2989G Dimensions Min: 70 in. (1780 mm) Max: 84 in. (2130 mm) 76 in. (1930 mm) 52 in. (1320 mm) WLE Min: 70 in. (1780 mm) Max: 84 in. (3130 mm) 38 in. (965 mm) 104 in. (2640 mm)
Page 61 - Notes
Page 62 - Graco Standard Warranty; Graco Information
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 Eng...
