Graco XP

Operation, Repair, and Parts
XP™ and XP-h™

3A0420ZAC
Proportioners EN
Mechanically linked fixed ratio plural-component system used for proportioning, mixing, and
spraying two component coatings. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations except where indicated in
the Models section.
Important Safety Instructions

Read all warnings and instructions in this
manual and in related manuals. Save these
instructions.
See Models section (starting on page 11) for model

numbers, descriptions, and agency approval
designations.
WLD
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 B Component Adjustable Fluid Restrictor . . . . . . . . . . . . . . . . 42
Important Isocyanate (ISO) Information . . . . . . . . . . . . . . . . . . . . 7 Flush Mixed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Flush Mix Manifold, Hose, and Spray Gun . . . . . . . . . . . . . . 43
Keep Components A and B Separate . . . . . . . . . . . . . . . . . . . 7 Empty and Flush Entire System
Moisture Sensitivity of Isocyanates . . . . . . . . . . . . . . . . . . . . . 8 (new system or end of job) . . . . . . . . . . . . . . . . . . . . . . . . 45
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 System Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Over Pressure Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hose Electrical Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
XP 35 with NXT Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
XP 35 with NXT Air Motor (continued) . . . . . . . . . . . . . . . . . . 13 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
XP50 with NXT 6500 Air Motor . . . . . . . . . . . . . . . . . . . . . . . 14 Change the Mix Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
XP50 with NXT 6500 Air Motor (continued) . . . . . . . . . . . . . . 15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
XP70 with NXT 6500 Air Motor . . . . . . . . . . . . . . . . . . . . . . . 16 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
XP70 with NXT 6500 Air Motor (continued) . . . . . . . . . . . . . . 17 Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
XP Systems with No Lowers . . . . . . . . . . . . . . . . . . . . . . . . . 18 Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
XP-h with Viscount II Hydraulic Motor . . . . . . . . . . . . . . . . . . 19 Mix Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Bare Proportioning Pump Packages . . . . . . . . . . . . . . . . . . . 20 Fluid Circulation Manifold with
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Over Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . 56
XP Proportioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
XP-h Proportioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fluid Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Fluid Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Main Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
45:1 Solvent Flush Pump Kit 262393 (optional) . . . . . . . . . . . 24 System Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Parts Varying by Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
*Bleed Type Motor Air Valve (CA) . . . . . . . . . . . . . . . . . . . . . 25 Parts Varying by Model (continued) . . . . . . . . . . . . . . . . . . . 63
*Air Pressure Relief Valve (CG) . . . . . . . . . . . . . . . . . . . . . . . 25 PressureTrak Kit 17G808 . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
*Air Filter (CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Bare Proportioning Pump Package . . . . . . . . . . . . . . . . . . . 71
*Air Regulator Adjustment (CB) . . . . . . . . . . . . . . . . . . . . . . . 25 Air Controls, 258983 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Fluid Line Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Fluid Circulation Manifold with
Initial System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Over Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . 74
Flush Before Using Equipment . . . . . . . . . . . . . . . . . . . . . . . 26 Heated Hose Recirculation Pump . . . . . . . . . . . . . . . . . . . . . 75
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Hose Heater (bracket mounted) . . . . . . . . . . . . . . . . . . . . . . 76
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Enclosure Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Enclosure Junction Box (continued) . . . . . . . . . . . . . . . . . . . 79
Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Heater Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Power Cord Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Heater Block Remote Manifold Kit . . . . . . . . . . . . . . . . . . . . 82
Wire Systems with Explosion-Proof Heaters . . . . . . . . . . . . . 30 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Motor Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Connect Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Acceptable For Use in Explosive Atmospheres . . . . . . . . . . 84
Connect Hydraulic Supply/Return Lines . . . . . . . . . . . . . . . . 31 Not Approved For Explosive Atmospheres . . . . . . . . . . . . . . 85
Connect Static Mixers, Gun, and Hoses . . . . . . . . . . . . . . . . 31 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Connect Fluid Hose Bundles (Remote Mix Manifold Only) . . 32 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Connecting Additional Hose Lengths . . . . . . . . . . . . . . . . . . . 32 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Prime Empty System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Prime A and B Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Prime Solvent Flush Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Recirculate Prior to Spraying or
Re-Prime After a Pump Runs Dry . . . . . . . . . . . . . . . . . 38
2 3A0420ZAC
Related Manuals
Related Manuals
Manuals are available at www.graco.com. Component manuals in English:
Manual Description
312145 XTR™ 5 and XTR™ 7 Spray Guns, Instructions - Parts
Pump Package Components
307158 ®
Viscount II Hydraulic Motor, Instructions - Parts
311238 NXT® Air Motor, Instructions - Parts
311762 Xtreme® Displacement Pumps, Instructions - Parts
334914 GH™ Power Pack, Instructions - Parts
Hopper Kits
312747 20 Gallon Double Wall Hopper Kit, Instructions - Parts
406860 7 Gallon Hopper Installation Kit, Instructions - Parts
Heating
309524 Viscon® HP Heater, Instructions - Parts
309525 Heated Hose Kit, Instructions - Parts
313259 Hopper or Hose Heat Circulation Kit, Instructions - Parts
406861 Heater Adapter Kit, Instructions - Parts
3A2954 Viscon HF Heater, Instructions - Parts
Solvent Flush
310863 Feed and Solvent Flush Kits, Instructions - Parts
312794 Merkur® Pump Assembly, Instructions - Parts
Accessories and Kits
309852 Polyurethane Circulation and Return Tube Kits, Instructions - Parts
311486 DataTrak™ Conversion Kit, Instructions - Parts
3A3320 XP and XP-hf PressureTrak Kit, Instructions - Parts
3A1331 XP Pressure Monitor Kit, Instructions - Parts
312769 Feed Pump and Agitator Kits, Instructions - Parts
339361 High Pressure Hose and Accessories, Brochure
3A0421 Ratio Check Kit, Instructions - Parts
3A0590 Mix Manifold, Quickset Mix Manifold, Instructions - Parts
3A2573 Gun Splitter Valve with Independent Flush, Instructions - Parts
406739 Desiccant Kit, Instructions - Parts
3A0420ZAC 3
Warnings
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.
FIRE AND EXPLOSION HAZARD

WARNING
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or sol-
vent 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 area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• 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.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static 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.
Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable
vapors. To help prevent fire and explosion:
• Clean plastic parts only in well ventilated area.
• Do not clean with a dry cloth.
• Do not operate electrostatic guns in equipment work area.
SPECIAL CONDITIONS FOR SAFE USE

• If using the Viscon HP and HF Heaters see manuals for special conditions for safe use.
• If using the PressureTrak, see the manual for special conditions for safe use.
4 3A0420ZAC
Warnings
SKIN INJECTION HAZARD

WARNING
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.
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 equip-
ment, follow the Pressure Relief Procedure and disconnect all power sources.
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.
3A0420ZAC 5
Warnings
EQUIPMENT MISUSE HAZARD

WARNING
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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Speci-
fications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For com-
plete information about your material, request Safety Data Sheet (SDS) 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 man-
ufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and cre-
ate 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.
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 reaction; burns; eye injury
and hearing loss. This protective equipment includes but is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and
local regulatory authority.
• Protective eyewear and hearing protection.
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 Safety Data Sheets (SDSs) for handling instructions and to know the specific hazards of the
fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area well-ven-
tilated and always wear appropriate personal protective equipment. See Personal Protective
Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
6 3A0420ZAC
Important Isocyanate (ISO) Information

Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions Keep Components A and B

Separate
Spraying or dispensing fluids that contain isocyanates

creates potentially harmful mists, vapors, and atom-
ized particulates. Cross-contamination can result in cured material in
• Read and understand the fluid manufacturer’s fluid lines which could cause serious injury or damage
warnings and Safety Data Sheets (SDSs) to know equipment. To prevent cross-contamination:
specific hazards and precautions related to isocya- • Never interchange component A and component B
nates. wetted parts.
• Use of isocyanates involves potentially hazardous • Never use solvent on one side if it has been con-
procedures. Do not spray with this equipment taminated from the other side.
unless you are trained, qualified, and have read
and understood the information in this manual and
in the fluid manufacturer’s application instructions
and SDSs.
• Use of incorrectly maintained or mis-adjusted
equipment may result in improperly cured material.
Equipment must be carefully 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 contact with isocyanates. Everyone
in the work area must wear chemically imperme-
able gloves, protective clothing and foot coverings
as recommended by the fluid manufacturer and
local regulatory authority. Follow all fluid manufac-
turer recommendations, including those regarding
handling of contaminated clothing. After spraying,
wash hands and face before eating or drinking.
3A0420ZAC 7
Moisture Sensitivity of Changing Materials

Isocyanates
NOTICE
Exposure to moisture (such as humidity) will cause ISO Changing the material types used in your equipment
to partially cure, forming small, hard, abrasive crystal requires special attention to avoid equipment damage
that become suspended in the fluid. Eventually a film will and downtime.
form on the surface and the ISO will begin to gel,
increasing in viscosity. • When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
NOTICE • Always clean the fluid inlet strainers after flushing.
Partially cured ISO will reduce performance and the • Check with your material manufacturer for chemi-
life of all wetted parts. cal compatibility.
• Always use a sealed container with a desiccant • When changing between epoxies and urethanes
dryer in the vent, or a nitrogen atmosphere. Never or polyureas, disassemble and clean all fluid com-
store ISO in an open container. ponents and change hoses. Epoxies often have
• Keep the ISO pump wet cup or reservoir (if amines on the B (hardener) side. Polyureas often
installed) filled with appropriate lubricant. The have amines on the B (resin) side.
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 appropri-
ate lubricant when reassembling.
NOTE: The amount of film formation and rate of crystal-

lization varies depending on the blend of ISO, the
humidity, and the temperature.
8 3A0420ZAC
A and B Component Designations

Material suppliers and markets refer to plural component materials differently. The table below summarizes the differ-
ent designations for the components used in various machines.
Market Equipment Designations Machine Left Side Machine Right Side

Letter A B
Color Red Blue
Foam and Poly- All Reactors,
urea, and Urethane HFR™, ISO, Hardener,
Component Names Polyol, Resin, Base
Pour Catalyst
and VRM™
Major or Minor Component
Low Volume Side High Volume Side
(when not 1:1 mix)
Letter A B
® Color Blue Green
Epoxy and Hydra-Cat ,
Urethane Protective XtremeMix™, Component Names Resin, Base Hardener, Catalyst
Coatings XM™, and XP Major or Minor Component
High Volume Side Low Volume Side
(when not 1:1 mix)
Letter A B
Color Red Blue
Epoxy, Silicone,
ISO, Hardener,
Urethanes, and PR70™ and PR Component Names Polyol, Resin, Base
other materials Catalyst
Major or Minor Component
High Volume Side Low Volume Side
(when not 1:1 mix)
3A0420ZAC 9
Overview
Overview
Usage Over Pressure Protection

The XP system is a mechanically linked fixed ratio sys-
tem that can mix and spray most two-component epoxy
and urethane protective coatings.
When using quick-setting material (less than 10 minute Mechanically linked pumps can create excessive fluid
pot life), the Remote Manifold Heater Block Kit (24Z934) pressure if the full motor force is applied to only one of
is recommended for use (included in complete sys- the fluid pumps.
tems).
• Cart-Mounted Systems Only: Maximum air pressure
set point blow off valves are provided to limit maxi-
The two pumps are carbide seat severe duty positive
mum fluid pressure. Do not remove these valves.
displacement pumps that displace fluid on both strokes.
• Color coded automatic over pressure relief valves
are used on cart-mounted systems to dump excess
fluid pressure back to the supply. Never plug these
return hoses. See Fluid Circulation Manifold with
Over Pressure Relief Valves on page 56.
Using an XP system, or components on the system,
not approved for hazardous locations or explosive • When using an XP bare pump package to build a
atmospheres may result in a fire or explosion hazard. system, use the over pressure relief valves refer-
enced above.
The XP systems are not approved for use in hazard-
• Never install individual shut off valves on the “A” and
ous locations unless the base model, all accessories,
“B” lines. On cart-mounted systems, common han-
all kits, and all wiring meet local, state, and national
dles link the fluid control valves.
codes.
• A rupture disc is provided on the small side fluid
See Wire Systems with Explosion-Proof Heaters on pump (pumps 145 cc and smaller) as a back-up to
page 30. the over pressure relief valve. If the rupture disc ever
opens, do not operate the machine until the over
pressure valve and the rupture disc have been
replaced.
• If changing pump lowers or motor on your system,
use the correct over pressure relief valves from the
chart on page 57.
10 3A0420ZAC
Approvals
Approvals
All systems CE marked except where noted by #.
All systems noted by X (in Approval column) are Ex marked.

II 2 G c llA T3
Models
NOTE: See special conditions for safe use in Viscon HF
Heater manual (3A2954) and Viscon HP Heater Manual
(309524).
Using an XP system, or components on the system, not
Pump sizes are marked on the pump cylinder; sizes are
approved for hazardous locations or explosive atmo-
nominal. See technical data in manual 311762 for actual
spheres may result in a fire or explosion hazard.
displacement.
The XP systems are not approved for use in hazardous
locations unless the base model, all accessories, all
kits, and all wiring meet local, state, and national codes.
See Wire Systems with Explosion-Proof Heaters on
page 30.
3A0420ZAC 11
Models
XP 35 with NXT Air Motor
Max Regulat-
Pump Volume
ed Air psi Specifications Includes Approval
Package Mix Ratio
(MPa, bar)
HP Non-Hazardous Location Hose Heater

HP Hazardous Location Hose Heater
HP Hazardous Location Heaters
Hose Heat Circulation Pump

Max Fluid Working Pressure
HP Non-Hazardous Heater
35 ft. (10.7m) Fluid Hose

Wiring Junction Box
XTR504 Spray Gun

7 Gallon Hoppers
Pressure Ratio
100 (0.70, 7.0)
psi (MPa, bar)
Solvent Pump
PressureTrak
85 (0.59, 5.9)
90 (0.62, 6.2)
95 (0.65, 6.5)
Models
(Fluid to Air)
Ex Marked
281100
281200
262803
281300
281400
1.0 : 1
2.0 : 1
2.5 : 1
3.0 : 1
4.0 : 1
281101 X X X 3500 38:1 X X X

281102 X X X 3500 38:1 X X X X
281103 X X X 3500 38:1 X X X X X
281104 X X X 3500 38:1 X X X X X X
574105 X X X 3500 38:1 X X X X X X
574106 X X X 3500 38:1 X X X X X X X X X
574107 X X X 3500 38:1 X X X X X X X X X
281201 X X X 3500 40:1 X X X

281202 X X X 3500 40:1 X X X X
281203 X X X 3500 40:1 X X X X X
281204 X X X 3500 40:1 X X X X X X
574205 X X X 3500 40:1 X X X X X X
574206 X X X 3500 40:1 X X X X X X X X X
574207 X X X 3500 40:1 X X X X X X X X X
262804 X X X 3400 34:1 X X X

281252 X X X 3400 34:1 X X X X
281253 X X X 3400 34:1 X X X X X
281254 X X X 3400 34:1 X X X X X X
574255 X X X 3400 34:1 X X X X X X
574256 X X X 3400 34:1 X X X X X X X X X
574257 X X X 3400 34:1 X X X X X X X X X
12 3A0420ZAC
Models
XP 35 with NXT Air Motor (continued)
Max Regulat-
Pump Volume Specifica-
ed Air psi Includes Approval
Package Mix Ratio tions
(MPa, bar)


HP Non-Hazardous Heater

Wiring Junction Box
XTR504 Spray Gun

7 Gallon Hoppers
Pressure Ratio
100 (0.70, 7.0)
psi (MPa, bar)
Solvent Pump
PressureTrak
85 (0.59, 5.9)
90 (0.62, 6.2)
95 (0.65, 6.5)
Models
(Fluid to Air)
Ex Marked
281100
281200
262803
281300
281400
1.0 : 1
2.0 : 1
2.5 : 1
3.0 : 1
4.0 : 1
281301 X X X 3500 36:1 X X X

281302 X X X 3500 36:1 X X X X
281303 X X X 3500 36:1 X X X X X
281304 X X X 3500 36:1 X X X X X X
574305 X X X 3500 36:1 X X X X X X
574306 X X X 3500 36:1 X X X X X X X X X
574307 X X X 3500 36:1 X X X X X X X X X
281401 X X X 3500 38:1 X X X

281402 X X X 3500 38:1 X X X X
281403 X X X 3500 38:1 X X X X X
281404 X X X 3500 38:1 X X X X X X
574405 X X X 3500 38:1 X X X X X X
574406 X X X 3500 38:1 X X X X X X X X X
574407 X X X 3500 38:1 X X X X X X X X X
3A0420ZAC 13
Models
XP50 with NXT 6500 Air Motor
Maximum
Pump Package Volume Mix Ratio Regulator Air Specifications Includes Approvals
psi (MPa, bar)

HP Non-Hazardous Location Heaters
PressureTrak (Hazardous Location)



Wiring Junction Box
XTR504 Spray Gun

7 Gallon Hoppers
Pressure Ratio
100 (0.70, 7.0)
psi (MPa, bar)
Solvent Pump
85 (0.59, 5.9)
90 (0.62, 6.2)
95 (0.65, 6.5)
Models
(Fluid to Air)
Ex Marked
282100
282150
282200
282250
282300
282330
282400
1.0 : 1
1.5 : 1
2.0 : 1
2.5 : 1
3.0 : 1
4.0 : 1
3.3 :1
282101 X X X 4500 45:1 X X X

282102 X X X 4500 45:1 X X X X
282103 X X X 4500 45:1 X X X X X
282104 X X X 4500 45:1 X X X X X X
575105 X X X 4500 45:1 X X X X X X
575106 X X X 4500 45:1 X X X X X X X X X
575107 X X X 4500 45:1 X X X X X X X X X
282151 X X X 5000 55:1 X X X

282152 X X X 5000 55:1 X X X X
282153 X X X 5000 55:1 X X X X X
282154 X X X 5000 55:1 X X X X X X
575155 X X X 5000 55:1 X X X X X X
575156 X X X 5000 55:1 X X X X X X X X X
575157 X X X 5000 55:1 X X X X X X X X X
282201 X X X 4800 48:1 X X X

282202 X X X 4800 48:1 X X X X
282203 X X X 4800 48:1 X X X X X
282204 X X X 4800 48:1 X X X X X X
575205 X X X 4800 48:1 X X X X X X
575206 X X X 4800 48:1 X X X X X X X X X
575207 X X X 4800 48:1 X X X X X X X X X
282251 X X X 5000 52:1 X X X

282252 X X X 5000 52:1 X X X X
282253 X X X 5000 52:1 X X X X X
282254 X X X 5000 52:1 X X X X X X
575255 X X X 5000 52:1 X X X X X X
575256 X X X 5000 52:1 X X X X X X X X X
575257 X X X 5000 52:1 X X X X X X X X X
14 3A0420ZAC
Models
XP50 with NXT 6500 Air Motor (continued)
Maximum
psi (MPa, bar)




Wiring Junction Box
XTR504 Spray Gun

7 Gallon Hoppers
Pressure Ratio
100 (0.70, 7.0)
psi (MPa, bar)
Solvent Pump
85 (0.59, 5.9)
90 (0.62, 6.2)
95 (0.65, 6.5)
Models
(Fluid to Air)
Ex Marked
282100
282150
282200
282250
282300
282330
282400
1.0 : 1
1.5 : 1
2.0 : 1
2.5 : 1
3.0 : 1
4.0 : 1
3.3 :1
282301 X X X 4500 45:1 X X X

282302 X X X 4500 45:1 X X X X
282303 X X X 4500 45:1 X X X X X
282304 X X X 4500 45:1 X X X X X X
575305 X X X 4500 45:1 X X X X X X
575306 X X X 4500 45:1 X X X X X X X X X
575307 X X X 4500 45:1 X X X X X X X X X
282331 X X X 5000 56:1 X X X

282332 X X X 5000 56:1 X X X X
282333 X X X 5000 56:1 X X X X X
282334 X X X 5000 56:1 X X X X X X
282401 X X X 4800 48:1 X X X

282402 X X X 4800 48:1 X X X X
282403 X X X 4800 48:1 X X X X X
282404 X X X 4800 48:1 X X X X X X
575405 X X X 4800 48:1 X X X X X X
575406 X X X 4800 48:1 X X X X X X X X X
575407 X X X 4800 48:1 X X X X X X X X X
3A0420ZAC 15
Models
XP70 with NXT 6500 Air Motor

Maximum
psi (MPa, bar)



35 ft. (10.7 m) Fluid Hose

Wiring Junction Box
XTR704 Spray Gun

7 Gallon Hoppers
Pressure Ratio
100 (0.70, 7.0)
psi (MPa, bar)
Solvent Pump
80 (0.55, 5.5)
90 (0.62, 6.2)
95 (0.65, 6.5)
Models
(Fluid to Air)
Ex Marked
571100
571150
571200
571250
571300
571400
1.0 : 1
1.5 : 1
2.0 : 1
2.5 : 1
3.0 : 1
4.0 : 1
571101 X X X 7250 73:1 X X X

571102 X X X 7250 73:1 X X X X
571103 X X X 7250 73:1 X X X X X
571104 X X X 7250 73:1 X X X X X X
576105 X X X 7250 73:1 X X X X X X
576106 X X X 7250 73:1 X X X X X X X X X
576107 X X X 7250 73:1 X X X X X X X X X
571151 X X X 7250 91:1 X X X

571152 X X X 7250 91:1 X X X X
571153 X X X 7250 91:1 X X X X X
571154 X X X 7250 91:1 X X X X X X
576155 X X X 7250 91:1 X X X X X X
576156 X X X 7250 91:1 X X X X X X X X X
576157 X X X 7250 91:1 X X X X X X X X X
571201 X X X 7250 76:1 X X X

571202 X X X 7250 76:1 X X X X
571203 X X X 7250 76:1 X X X X X
571204 X X X 7250 76:1 X X X X X X
576205 X X X 7250 76:1 X X X X X X
576206 X X X 7250 76:1 X X X X X X X X X
576207 X X X 7250 76:1 X X X X X X X X X
571251 X X X 6500 65:1 X X X

571252 X X X 6500 65:1 X X X X
571253 X X X 6500 65:1 X X X X X
571254 X X X 6500 65:1 X X X X X X
576255 X X X 6500 65:1 X X X X X X
576256 X X X 6500 65:1 X X X X X X X X X
576257 X X X 6500 65:1 X X X X X X X X
16 3A0420ZAC
Models
XP70 with NXT 6500 Air Motor (continued)

Maximum
psi (MPa, bar)



35 ft. (10.7 m) Fluid Hose

Wiring Junction Box
XTR704 Spray Gun

7 Gallon Hoppers
Pressure Ratio
100 (0.70, 7.0)
psi (MPa, bar)
Solvent Pump
85 (0.59, 5.9)
90 (0.62, 6.2)
95 (0.65, 6.5)
Models
(Fluid to Air)
Ex Marked
571100
571150
571200
571250
571300
571400
1.0 : 1
1.5 : 1
2.0 : 1
2.5 : 1
3.0 : 1
4.0 : 1
571301 X X X 6800 68:1 X X X

571302 X X X 6800 68:1 X X X X
571303 X X X 6800 68:1 X X X X X
571304 X X X 6800 68:1 X X X X X X
576305 X X X 6800 68:1 X X X X X X
576306 X X X 6800 68:1 X X X X X X X X X
576307 X X X 6800 68:1 X X X X X X X X X
571401 X X X 7250 73:1 X X X

571402 X X X 7250 73:1 X X X X
571403 X X X 7250 73:1 X X X X X
571404 X X X 7250 73:1 X X X X X X
576405 X X X 7250 73:1 X X X X X X
576406 X X X 7250 73:1 X X X X X X X X X
576407 X X X 7250 73:1 X X X X X X X X X
3A0420ZAC 17
Models
XP Systems with No Lowers

Pump
Package
Compatible Recirculation
without Includes # Approvals
To Manifold
Pump
Lowers
262784 (purple over-pressure valve)
262806 (silver over-pressure valve)

262783 (gold over-pressure valve)
10 ft. Recirculation Hose

Models
10 ft. Whip Hose

25 ft. Fluid Hose
XP System
Spray Gun
Ex Marked
CE Rated
24M422
24M423
281000 XP35 X X XTR504 H43825 H42510 H52510
282000 XP50 X X XTR504 H53825 H52510 H52510
571000 XP70 X X XTR704 H73825 H72510 H52510
# These models without pump lowers are not operational and are not CE rated or Ex marked.
18 3A0420ZAC
Models
XP-h with Viscount II Hydraulic Motor

Pump Volume
Specifications Includes Approvals
Package Mix Ratio
Maximum Hydraulic Oil Working Pressure

Maximum Fluid Working Pressure
35 ft (10.7 m) Supply Hose

XTR504 Spray Gun
XTR704 Spray Gun
(Fluid to Hydraulic)
7 Gallon Hoppers
Pressure Ratio
psi (MPa, bar)
psi (MPa, bar)
Solvent Pump
Models
Ex Marked
284102
284202
284252
284302
284402
284103
284203
284253
284303
284403
1.0:1
2.0:1
2.5:1
3.0:1
4.0:1
XPh-50:
284104 X X 4700 1800 2.6:1 X X X
284204 X X 5050 1800 2.8:1 X X X
284254 X X 5000 1650 3.0:1 X X X
284304 X X 4700 1800 2.6:1 X X X
284404 X X 5000 1800 2.8:1 X X X
284105 X X 4700 1800 2.6:1 X X X X X
284205 X X 5050 1800 2.8:1 X X X X X
284255 X X 5000 1650 3.0:1 X X X X X
284305 X X 4700 1800 2.6:1 X X X X X
284405 X X 5000 1800 2.8:1 X X X X X
XPh-70:
284106 X X 7100 1700 4.2:1 X X X
284206 X X 7200 1650 4.4:1 X X X
284256 X X 6800 1800 3.8:1 X X X
284306 X X 7100 1800 4.0:1 X X X
284406 X X 7150 1700 4.2:1 X X X
284107 X X 7100 1700 4.2:1 X X X X X
284207 X X 7200 1650 4.4:1 X X X X X
284257 X X 6800 1800 3.8:1 X X X X X
284307 X X 7100 1800 4.0:1 X X X X X
284407 X X 7150 1700 4.2:1 X X X X X
3A0420ZAC 19
Models
Bare Proportioning Pump Packages

Packages include motor, pump lowers, and all connec- NOTE: All pump packages are Ex rated except for the
tion hardware. XP-h pump packages (284xxx):
II 2 G c IIA T3
Building systems with bare proportioning pump Hydraulically powered pump packages (XP-h) are not
packages: available as complete systems. Refer to manual 307158
for hydraulic application information.
• Over Pressure Protection must be used, see
page 10. See chart on page 57 to identify the over
pressure relief valves to use with your system. Pump sizes are marked on the pump cylinder; sizes are
• All components must meet or exceed maximum nominal. See technical data in manual 311762 for actual
working pressures. displacement.
Over
Combined Maximum Fluid Maximum Air/ Pressure
Volume Fluid Fluid Flow Working Hydraulic Oil Relief
Pump A Side B Side Mix Output Pressure at 40 cpm Pressure Working Pressure Valve To Ex
Type Package Pump Pump Ratio cc/cycle Ratio gpm (lpm) psi (MPa, bar) psi (MPa, bar) Use Rated
281100 L090C0 L090C0 1.0:1 180 38:1 1.9 (7.2) 3500 (24, 241) 95 (0.65, 6.5)
XP35 with
NXT 3400
281200 L115C0 L058C0 2.0:1 173 40:1 1.8 (6.8) 3500 (24, 241) 85 (0.59, 5.9)
Air Motor
262803 L14AC0 L058C0 2.5:1 202 34:1 2.1 (7.9 3500 (24, 241) 100 (0.7, 7) Purple
281300 L14AC0 L048C0 3.0:1 192 36:1 2.0 (7.6) 3400 (23, 234) 95 (0.65, 6.5)
281400 L14AC0 L036C0 4.0:1 180 38:1 1.9 (7.2) 3500 (24, 241) 90 (0.62, 6.2)
282100 L14AC0 L14AC0 1.0:1 288 45:1 3.1 (11.7) 4500 (31, 310) 100 (0.7, 7)
282150 L14AC0 L097C0 1.5:1 240 55:1 2.6 (9.8) 5000 (34, 345) 90 (0.62, 6.2)
XP50 with
NXT 6500
282200 L18AC0 L090C0 2.0:1 270 48:1 2.9 (11.0) 4800 (33, 331) 100 (0.7, 7)
Air Motor
282250 L18AC0 L072C0 2.5:1 252 52:1 2.7 (10.2) 5000 (34, 345) 95 (0.65, 6.5) Gold

282300 L22AC0 L072C0 3.0:1 288 45:1 3.1 (11.7) 4500 (31, 310) 100 (0.7, 7)
282330 L18AC0 L054C0 3.3:1 234 56:1 2.5 (9.5) 5000 (34, 345) 95 (0.65, 6.5)
282400 L22AC0 L054C0 4.0:1 270 48:1 2.9 (11.0) 4800 (33, 331) 100 (0.7, 7)
571100 L090C0 L090C0 1.0:1 180 72:1 1.9 (7.2) 7250 (50, 500) 100 (0.7, 7)
571150 L085C0 L058C0 1.5:1 144 91:1 1.5 (5.6) 7250 (50, 500) 80 (0.55, 5.5)
XP70 with
NXT 6500
Air Motor
571200 L115C0 L058C0 2.0:1 174 76:1 1.8 (6.8) 7250 (50, 500) 95 (0.65, 6.5)
Silver
571250 L14AC0 L058C0 2.5:1 203 65:1 2.1 (7.9) 6500 (45, 448) 100 (0.7, 7)
571300 L14AC0 L048C0 3.0:1 193 68:1 2.0 (7.5) 6500 (45, 448) 100 (0.7, 7)
571400 L14AC0 L036C0 4.0:1 181 73:1 1.9 (7.2) 7250 (50, 500) 100 (0.7, 7)
284101 L22AC0 L22AC0 435 1.75:1 4.6 (17.4) 3150 (22, 217) 1800 (12, 124) Purple
284102 L14AC0 L14AC0 1.0:1 293 2.63:1 3.1 (11.7) 4700 (32, 324) 1800 (12, 124) Gold
284103 L090C0 L090C0 180 4.21:1 1.9 (7.2) 7150 (49, 493) 1700 (12, 117) Silver
284201 L29AC0 L14AC0 435 1.75:1 4.6 (17.4) 3150 (22, 217) 1800 (12, 124) Purple
284202 L18AC0 L090C0 2.0:1 274 2.81:1 2.9 (11.0) 5050 (35, 348) 1800 (12, 124) Gold
284203 L115C0 L058C0 170 4.39:1 1.8 (6.8) 7200 (50, 496) 1650 (11, 114) Silver
Hydraulic Motor
Viscount II
284251 L29AC0 L115C0 407 1.88:1 4.3 (16.3) 3400 (23, 234) 1800 (12, 124) Purple
XP-h with
284252 L18AC0 L072C0 2.5:1 255 3.02:1 2.7 (10.2) 5000 (34, 345) 1650 (11, 114) Gold
284253 L14AC0 L058C0 199 3.77:1 2.1 (7.9) 6800 (47, 469) 1800 (12, 124) Silver
284301 L29AC0 L097C0 388 1.97:1 4.1 (15.5) 3500 (24, 241) 1800 (12, 124) Purple
284302 L22AC0 L072C0 3.0:1 293 2.63:1 3.1 (11.7) 4700 (32, 324) 1800 (12, 124) Gold
284303 L14AC0 L048C0 189 3.95:1 2.0 (7.6) 7100 (49, 490) 1800 (12, 124) Silver
284401 L29AC0 L072C0 360 2.10:1 3.8 (14.4) 3800 (26, 262) 1800 (12, 124) Purple
284402 L22AC0 L054C0 4.0:1 274 2.80:1 2.9 (11.0) 5000 (34, 345) 1800 (12, 124) Gold
284403 L14AC0 L036C0 180 4.21:1 1.9 (7.2) 7150 (49, 493) 1700 (12, 117) Silver
20 3A0420ZAC
Component Identification
XP Proportioners
$)
$% ( $$
%
; $*
0
5
= &) 3
8 9
$ 7
/ * 6
<
1
$(
'
WLD
- )
$& .
:
$'
+ &
&&
50
FIG. 1: XP70 Complete System (model 576107 shown)
Key:
A Air Supply Hose for Motor T Yoke With Rod Bearings
B Main Air Controls; see page 23 U Recirculation Lines
C Air Inlet - 3/4 npsm(f) V Yoke Position Nut
D High Pressure Fluid Pump W Static Mixer Tubes with Replacement Plastic Elements
E Air Motor X Motor Position Indicator Lines; see Motor Position on
F Fluid Heater page 30
G Solvent Flush Pump; see page 24 Y Over Pressure Rupture Disc;
H Solvent Flush Pump Air Controls; see page 24 Z Air Motor Ground Wire
J 7 Gallon Hoppers AA PressureTrak
K Cart AB Junction Box
L Brake AC Circulation Pump Reservoir
M Handle (lift to release) AD Circulation Pump
N Fluid Control Assembly; see page 23 AE Viscon HP Hose Water Heater
P Tie Rods AF Heater ON/OFF Switches
R Motor Adapter Plate AG Power Disconnect Switch
S Adjustable Packing Nuts with Wet Cups
3A0420ZAC 21
XP-h Proportioners
Mounting Components for

Pump Package
M
E
G
R
X
U
H
F
N
V P
J T
S
Y
K
D D
L
W
FIG. 2: XP70 System with Optional Accessories

Key:
D High Pressure Fluid Pump S Adjustable Packing Nuts with Wet Cups
E Hydraulic Motor T Yoke With Rod Bearings
F Fluid Heater (optional) U Recirculation Lines
G Solvent Flush Pump (optional); see page 24 V Yoke Position Nut
H Solvent Flush Pump Air Controls; see page 24 W Static Mixer Tubes with Replacement Plastic Elements
J 7 Gallon Hoppers (optional) X Motor Position Indicator Lines; see Motor Position on
K Cart page 30
L Brake Y Over Pressure Rupture Disc;
M Handle (lift to release) only 38cc, 48cc, 54cc, 58cc, and 72cc pumps
N Fluid Control Assembly; see page 23
P Tie Rods
R Motor Adapter Plate
22 3A0420ZAC
Fluid Control Assembly

Standard Mix Manifold shown
AA
AH
AC Key:
AA Fluid Manifold
AB Mix Manifold
AM AC Circulation Handle (shown closed)
AF
AD Solvent Flush Valve
AE Dual Shutoff Handle (shown closed)
AF Fluid Pressure Gauges
AE AG Fluid Supply Inlet (Behind Fluid Manifold)
AH Fluid Circulation Fittings
AJ B Component Adjustable Fluid Restrictor; see page 42
AK A and B Mix Manifold Check Valves
AL Solvent Inlet Check Valve
AJ
AM Automatic, Spring Loaded, Color-Coded Over Pressure
Relief Valves; with grease fittings; see page 57
AL AN A and B Combined Outlet; 3/8 npt(m)
AB
AK
AN
AD
ti19167a
FIG. 3
Main Air Controls

For XP systems only.
CE CB
CA
Key:
CA Main Motor Shutoff Valve (Relieving)
CB Main Motor Air Pressure Regulator
CC Air Filter with Auto Drain
CC
CD Main Motor Air Pressure Gauge
CD CE Filtered Air Distribution Manifold
FIG. 4
3A0420ZAC 23
45:1 Solvent Flush Pump Kit 262393 (optional)

Pump
Key:
BA Solvent flush pump (Merkur Pump)
BA BB Fluid Inlet
BD Muffler
BE Prime/Flush/Sample valve
BD
BF Fluid Outlet Hose
BG Circulation hose
BF
BE
BG
BB (suction hose not shown)
r_571100_3a0420a_4a-2
FIG. 5
Air Controls
Key:
DC DA Solvent Pump Air Shutoff Valve (Relieving)
DB Solvent Pump Air Pressure Regulator
DC Solvent Pump Air Pressure Gauge
DD Air Outlet
DE Air Inlet
DE
DB
DA
DD
r_571101_3a0420a_5a-2
FIG. 6
24 3A0420ZAC
System Components
System Components
* Indicates a customer-supplied component required to add to Bare Pump Packages (part numbers ending in zero
“0”) to make a complete system.
*Bleed Type Motor Air Valve (CA) *Air Filter (CC)

Removes harmful dirt from compressed air supply. A
minimum 40 micron filter is used.
Trapped air can cause the pump to cycle unexpect- *Air Regulator Adjustment (CB)
edly, which could result in serious injury from splash-
ing or moving parts. Use the Bleed Type Master Air Adjusts air pressure to the motor and fluid outlet pres-
Valve to relieve trapped air. sure of pump. Locate the air regulator close to the
pump. Read air pressure on the gauge.
Be sure the valve is easily accessible from the pump
and located downstream from the air regulator (CB).
Fluid Line Components
The two steps below are required in your system to
relieve air trapped between the air motor when the valve • *Fluid Manifold (AA): Controls circulation and
is closed: pump priming.
1. Open the valve to supply air to the motor.
• *Mix Manifold (AB): Combines A and B fluid into
2. Close the valve to shut off air to the motor, and one fluid line.
bleed any trapped air from the motor.
• *Circulation Handle (AC): Directs fluid flow for cir-
culation or mixing. Move to open position to relieve
*Air Pressure Relief Valve (CG) fluid pressure, prime pumps, and circulate material
in hoppers. Move to closed position to spray mixed
Automatically opens to relieve air pressure if supplied
material.
pressure exceeds preset limit. Use the correct air pres-
sure relief valve for the system ratio:
• *Dual Shutoff Handle (AE): Controls A and B fluid
CG flow for mixing and dispensing. Close before flush-
ing.
• *Solvent Flush Valve (AD): Controls solvent flow

to the mix manifold, hose, and spray gun.
• *Static mixer/gun hose kit: Thoroughly mixes the

two fluids and delivers the mixed fluid to the spray
gun. Includes static mixer and hoses to the spray
gun.
See Models (page 11) for Maximum Regulated Air • Fluid Heaters (F): Heats the resin and hardener
Pressure to ensure proper air pressure relief valve before mixing. Improves the chemical reaction and
installed. lowers viscosity to improve the spray pattern.
Valve Part Pressure Relief psi (MPa, bar) • Solvent Flush Pump (ZD): Flushes the mix mani-
116643 85 (0.59, 5.9) fold. Includes a solvent pump, mounting hardware,
and solvent supply hose.
16D376 90 (0.62, 6.2)
114055 95 (0.65, 6.5)
113498 100 (0.70, 7.0)
3A0420ZAC 25
Initial System Setup
Initial System Setup

1. Check the shipment for accuracy. Ensure you have 8. Connect the fluid hose assembly, including the
received everything you ordered. See Component static mixers, whip hose and gun. See Connect
Identification, page 21. Static Mixers, Gun, and Hoses, page 31.
2. Check for loose fittings and fasteners. 9. Connect the battery in the PressureTrak module.
3. Systems supplied as complete are already con- 10. XP Units: Connect the air supply hose. See Con-
nected for fluid, air and electrical hookups. nect Air Supply, page 31.
4. If any accessories are added to a non-complete sys- XP-h Units: Connect the hydraulic lines. See man-
tem refer to Related Manuals, page 3. ual 334914 for instructions.
5. Install desiccant kits if using polyurethane isocya- Flush test oil from system as needed. See Pressure
nates in hoppers. See manual 406739 for instruc- Relief Procedure, page 34. See Empty and Flush
tions. Entire System, page 45.
6. Install circulation and return tube kits if you are feed-

ing material from drums or remote hoppers. See Flush Before Using Equipment
manual 309852 if you are feeding urethane mate- • The bare pump package was tested with lightweight
rial. oil, which is left in the fluid passages to protect
parts. To avoid contaminating your fluid with oil,
7. Connect the feed pumps, fluid strainers, and air
flush the equipment with a compatible solvent
hoses as necessary. For systems without hoppers,
before using the equipment. See Empty and Flush
see manual 312769.
Entire System, page 45.
26 3A0420ZAC
Setup
Setup
Location 1. Locate the proportioner on a level surface.
2. Position the proportioner for convenient operator

access and maintenance, proper routing of air and
fluid lines, and easy connection of components and
accessories.
Using an XP system, or components on the system, not
approved for hazardous locations or explosive atmo- 3. For permanent mounting, remove wheels and
spheres may result in a fire or explosion hazard. mount the frame to the floor. See Dimensions,
page 86.
The XP systems are not approved for use in hazardous
locations unless the base model, all accessories, all 4. Make sure cart brake (L) is in the locked position.
kits, and all wiring meet local, state, and national codes.
See Wire Systems with Explosion-Proof Heaters on
page 30.
3A0420ZAC 27
Setup
Grounding
2. Ground the object being sprayed, fluid supply con-
tainer, and all other equipment in the work area. Fol-
low your local code. Use only electrically conductive
air and fluid hoses.
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static 3. Ground all solvent pails. Use only metal pails, which
sparking can cause fumes to ignite or explode. are conductive, placed on a grounded surface. Do
Improper grounding can cause electric shock. not place pail on a non-conductive surface, such as
Grounding provides an escape wire for the electric paper or cardboard, which interrupts grounding con-
current. tinuity.
Tools Required: Solvent Pump: use ground wire and clamp (supplied
• Grounding wires and clamps for pails with solvent pump).
• Two 5 gallon (19 liter) metal pails
Pump:
1. Use the ground wire and clamp (supplied). Loosen
grounding lug locknut (W) and washer (X). Insert
ground wire end (Y) into lug (Z) slot and tighten
locknut securely. Connect ground clamp to a true =%
earth ground.
XP Units
*6
Y
WLD
Air and fluid hoses: use only static dissipation type

W, X, Z hoses with a maximum of 300 ft (91 m) combined hose
length to ensure grounding continuity. Check electrical
XP-h Units
resistance of hoses regularly. If total resistance to ground
exceeds 29 megohms, replace hose immediately.
W, X, Z Air compressor: follow manufacturer’s recommenda-

Y tions.
Spray gun: ground through connection to a properly

grounded fluid hose and pump.
WLD
28 3A0420ZAC
Setup
Connect Power
4. Route the power cable through the strain relief in
the electrical enclosure.
5. Connect incoming power wires as shown in the
All electrical wiring must be done by a qualified electri- Power Disconnect diagram below. Gently pull on
cian and comply with all local codes and regulations. all connections to verify that they are properly
secured.
NOTE: This wiring method converts three input power
types to 200-240 VAC, 1 Phase output power to all NOTE: Terminal jumpers are located inside the
heaters. electrical enclosure door.
1. Turn main power disconnect switch (ZP) OFF. 6. Install supplied terminal jumpers in the positions
shown in the Terminal Block diagram below for the
2. Open the electrical enclosure door. power source used.
3. See the Power Cord Requirements table to select 7. Verify that all items are connected properly as
proper input power cord. shown below, then close the electrical enclosure
door.
Power Disconnect
ti31899a
Terminal Block
ti31900a
Power Cord Requirements

Cord Specifications AWG Full Load Peak
Model Input Power
(mm^2) + Ground / PE Current (Amps)
57xxx5 200-240 VAC, 1 Phase 6 (13.3), 2 wire 58
(two fluid heaters with two 200-240 VAC, 3 Phase, DELTA 8 (8.4), 3 wire 51
optional hopper heaters) 350-415 VAC, 3 Phase, WYE 10 (5.3), 4 wire 40
57xxx7 200-240 VAC, 1 Phase 6 (13.3), 2 wire 75
(two fluid heaters, one 200-240 VAC, 3 Phase, DELTA 6 (13.3), 2 wire 65
hose heater with two 350-415 VAC, 3 Phase, WYE 10 (5.3), 4 wire 40
optional hopper heaters)
3A0420ZAC 29
Setup
Wire Systems with Change Motor Position

Explosion-Proof Heaters There are specific motor positions for each mix ratio set-
ting. To adjust the position of the air motor:
(Hazardous location systems only) 1. Perform Check Motor Position procedure. If posi-
tion is incorrect, continue to next step.
2. Loosen the eight fasteners and remove the two
pump guards.
Improperly installed or connected equipment will cre- fastener

ate a hazardous condition and cause fire, explosion,
or electric shock. Follow local regulations.
pump guard
If your system is rated for hazardous areas, and you
have explosion-proof heaters, you must have a quali-
fied electrician connect the heater wiring. Make sure
fastener
the wiring and installation comply with local electrical
codes for hazardous areas.
pump guard
When explosion-proof heaters are used, ensure the wir-
ing, wiring connections, switches, and electrical distribu-
3. Place wrench on adapter rod (104) then use sup-
tion panel all meet flame-proof (explosion-proof)
plied tool to loosen the serrated yoke nut (V) above
requirements.
the yoke (T).
Refer to the Viscon HP or HF heater manual for electri-
cal connection instructions and guidelines in hazardous 104
locations. V
T
Motor Position
The motor position must be set for the volume mix ratio 4. Loosen the three nuts (P2) below the motor tie rods.
of the system. E
NOTE: Changing the motor position does not change
the mix ratio. piston rod
Check Motor Position

1. Verify that the correct pumps are mounted for your V
mix ratio by volume. See chart in Bare Proportion- P2
ing Pump Packages on page 20.
T
indicator line
5. Grab the piston rod and slide the position of the
motor (E) until the indicator lines are aligned with
your ratio.
indicator line NOTICE
Do not hit tie rods (P) with a steel hammer. Damage
to the air motor base may result.
Air Motor shown
2. Verify that the motor position is adjusted correctly 6. Tighten the three nuts (P2) and yoke nut (V).
for that mix ratio. See FIG. 7. If not, perform the fol-
7. Use supplied tool to tighten the yoke nut, then install
lowing Change Motor Position procedure.
the pump guards.
30 3A0420ZAC
Setup
Connect Air Supply Connect Static Mixers, Gun, and

For XP systems only. Hoses
1. Connect the air supply hose to the 3/4 npt(f) air filter NOTICE
inlet (C). To prevent creating a flare on the mixer tube, do not
use a union swivel end on the mix tube inlet.
Use a 3/4 in. (19.1 mm) ID minimum air hose. Air con-
sumption is 75 cfm per gallon per minute spraying. Do 1. Connect the outlet of the two primary static mixer
not use pin fitting type quick disconnects. tubes with mixer elements (W) to the fluid mix
hose (25), cleanup mixer (27, 28), whip hose (30),
and spray gun (31).
2. Add mixed material hose as necessary between the

mix hose (25) and cleanup mixer (27, 28).
C plug
AB
AN
27, 28
2. Remove plugs as necessary for solvent pump and
feed supply pump air hoses. See pump manuals for 30
setup instructions. 25
31
Connect Hydraulic
Supply/Return Lines
Standard Mix Manifold shown
For XP-h systems only.
WLE
3A0420ZAC 31
Setup
Connect Fluid Hose Bundles 7. Connect the resin and hardener hoses to the mix
manifold.
(Remote Mix Manifold Only)
8. Connect the extension glycol tubing from the hose
NOTE: For all steps below refer to the illustration on the bundle to the heater block (HB). Cut the tubing
next page. squarely behind only one of the u-fittings. Connect
the two union fittings (10) to the hose tubing (one
Refer to the mix manifold manual 3A0590 for details
red, one blue). Cut the red tubing (11) piece and
when the mix manifold (AB) is remotely mounted.
blue tubing (12) piece to length to fit between the
hose bundle and heater block, then tighten the fit-
1. Connect additional resin and hardener fluid hose
tings.
sections to the proportioner fluid manifold (AA) out-
let. Hoses must be properly sized and balanced for
your mix ratio. Connecting Additional Hose
2. Connect the resin and hardener hoses to the resin Lengths
and hardener inlets on the mix manifold.
NOTE: For all steps below refer to the illustration on the
3. Connect the female quick-disconnect “Y” fitting next page.
assembly (FQ) to the blue tubing quick-disconnect
from below the overflow bottles. Up to six 50 ft (15.2 m) sections of heated hose can be
attached for a maximum total length of 300 ft (91.4 m).
4. Connect the male quick-disconnect “Y” fitting
assembly (MQ) to the red tubing quick-disconnect 1. Remove the elbow fittings at the end of the heated
from the heater outlet. hose assembly.
5. Connect the glycol circulation tubing to the “Y” fitting 2. Connect the next length of hose, using union fittings
assemblies. Cut the red and blue tubing squarely supplied with the hose.
behind the hose union fittings. Connect to the “Y” fit-
ting assembly. NOTE: The tubes are color coded. Make sure all
colors match when connecting the fittings.
NOTE: The tubes and fittings are color coded. Make
sure all colors match when connecting the fittings. NOTICE
To prevent cross-contamination, ensure you con-
6. Connect the mix manifold (MM) to the remote mani-
nect the “A” side fluid hose to the “A” side fluid hose
fold carriage (MC) heater block (HB) and bracket
using two screws (9). on the additional heated hose.
32 3A0420ZAC
Setup
Connecting Hoses
%/8(
A B
)4
5('
04
5('
%/8(
B A 00
%/8(
0&

WLE
5('
+%

3A0420ZAC 33
Pressure Relief Procedure
Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever 6. Disengage the trigger lock.
you see this symbol.
7. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
This equipment stays pressurized until pressure is

manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing fluid 8. Engage the gun trigger lock.
and moving parts, follow the Pressure Relief Proce-
dure when you stop spraying and before cleaning, 9. Close the dual shutoff handle (AE) and open the cir-
checking, or servicing the equipment. culation handle (AC) to relieve A and B fluid pres-
sure.
1. Engage the gun trigger lock.
AC
(open)
AE
(closed)
TI1949a
2. XP Systems:
r_571101_3A0420A_9a-2
Close the main air shutoff valve (CA).
NOTE: Always flush the mix hose after relieving A and B

fluid pressure through the mix manifold. Follow Flush
Mixed Material, page 43 when you stop spraying or dis-
CA pensing; and before cleaning, checking, servicing, or
transporting equipment.
r_571100_3A0420A_11a-1
NOTE: For longer valve life when using abrasive fluids,
it is advisable to relieve high pressure out through the
XP-h Systems: gun when possible.
Set pump valve off.
• If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved after follow-
ing the steps above, very slowly loosen tip guard
retaining nut or hose end coupling to relieve pres-
sure gradually, then loosen completely. Clear hose
or tip obstruction.
ti7108a
ti7108a • If static mixer, whip hose, and gun cannot be
flushed because of mixed and cured material, very
3. Shut off heaters, if used. slowly loosen static mixer tube from mix manifold
outlet to relieve pressure gradually, then loosen
4. Shut off feed pumps, if used.
completely. Replace or clean clogged components.
5. Remove the spray tip.
34 3A0420ZAC
Prime Empty System
Prime Empty System

Prime A and B Fluids 2. Fill the A and B hoppers with proper materials. Fill
the A side (blue) with major volume of material; fill
the B side (green) with minor volume of material
(unless 1:1 mix ratio).
3. Move the recirculation lines (U) to empty containers.
To help prevent injury, wear gloves when using solvents

and/or if the fluid temperature exceeds 110° F (48° C). 8
The equipment is tested with light weight oil at the fac-

tory. If necessary, flush out the oil with a compatible sol-
vent before spraying. See Empty and Flush Entire
System, page 45.
Do not install the gun spray tip yet. To avoid splashing,

use the lowest pressure possible to prime.
1. Condition the materials prior to adding to the hop-

pers (J). Ensure that the resin materials are thor-
oughly mixed, homogeneous, and pour-able prior to
adding to the hopper. Stir the hardeners back into
suspension prior to adding material to hopper.
WLD
4. Close the dual shutoff handle (AE) and open the cir-
culation handle (AC).
WLD
3A0420ZAC 35
Prime Empty System
5. XP Systems only: Open the main air shutoff valve 7. Decrease air pressure. Close the main air shutoff
(CA). Then slowly increase the air regulator pres- valve (CA).
sure (CB).
WLD
A B
XP-h Systems only: Set pump valve on. Then turn WLD
down the pressure control knob.

8. Move the recirculation lines (U) back to the correct
hopper (J).
ti7108a
ti7108a ti7111b
6. Dispense fluid into the containers until clean fluid

comes out of the A and B recirculation lines.
8
-
WLD
9. If using heaters, heat fluid throughout system before

spraying. See Recirculate Prior to Spraying or
Re-Prime After a Pump Runs Dry, page 38.
WLD
36 3A0420ZAC
Prime Empty System
Prime Solvent Flush Pump 6. Ensure the trigger lock is engaged. Remove the
spray tip.
Follow instructions if the solvent flush pump is used.
TI1949a
1. Connect a ground wire (not included) to a metal pail
4)!
TI1948a
of solvent.
7. Disengage the trigger lock and trigger the gun into a
2. Place the siphon tube and the solvent circulation grounded metal pail while holding against a pail.
hose (BG) in the pail of solvent. Use a pail lid with a hole to dispense through. Seal
around the hole and gun with a rag to prevent
BG splash back. Be careful to keep fingers away from
the front of the gun.
BE
r_571101_3A0420A_5b-2
TI1950a
3. Open the solvent prime valve (BE) on the solvent
pump (BA) outlet. 8. Open the solvent pump air valve (DA). Slowly turn
the solvent pump air regulator (DB) clockwise to
4. Open the solvent pump air valve (DA). Slowly turn
prime the solvent pump and push air out of the mix
the solvent pump air regulator (DB) clockwise to
hose and gun. Trigger the gun until all air is purged.
prime the solvent pump and route solvent back to
the pail. Close the solvent pump fluid valve (BE) and 9. Close the solvent pump air valve (DA) and trigger
air valve (DA). the gun to relieve pressure. Engage the trigger lock.
Replace the spray tip.
DB
DA
TI1949a
r_571101_3A0420A_5a-2 DA
5. Open the solvent flush valve (AD) on the mix mani- r_571101_3A0420A_12a-2
fold.
10. Close the solvent flush valve (AD).
NOTE: Solvent pump air and pressure may be left on

AE while spraying.
(closed)
NOTE: Never spray mixed material without the solvent
pump and hose primed with solvent for proper flushing
AB in time to clear the mixed material.
AD
3A0420ZAC 37
Prime Empty System
Recirculate Prior to Spraying or 4. Open the circulation valve handle (AC).
Re-Prime After a Pump Runs Dry

NOTE: Agitate, recirculate, and heat the material only
AC
as necessary to avoid mixing air into the fluid.
Use the recirculation mode when heating the material is

required. Note the temperature at the top of the heater
(outgoing or back to the hopper). When the thermome-
ter reaches operating temperature, the material is ready
to spray.
If using a system that does not require heat, recircula-

WLD
tion is still required prior to spraying. Recirculation
ensures that any settled fillers are mixed in, the pump
lines are fully primed, and the pump check valves are 5. For XP Systems:
operating smoothly. a. Turn down air pressure regulator (CB) and then
open the main air shutoff valve (CA). Use the air
Recirculation also allows you to re-prime one side that pressure regulator to slowly increase air pres-
has run dry. sure to pumps until they start running slowly.
1. Follow Prime Empty System, page 35.
2. Close the dual shutoff handle (AE). &$
AC
AE
WLD
b. Run the pumps for a few minutes or until the

material has reached the desired temperature.
3. Ensure the recirculation hoses (U) are in the correct See Heat Fluid, page 39.
hoppers (J).
c. Close the motor air shutoff valve (CA).
U
J
CA
38 3A0420ZAC
Prime Empty System
6. For XP-h Systems: Heat Fluid

a. Turn down the pressure control knob and set
the pump valve on. To heat fluid evenly throughout the system:
1. Circulate the fluid at approximately 1/2 gpm
(10-20 cycles/min.) to raise the temperature of the
hoppers to 80°-90° F (27°-32° C).
2. Decrease the circulation rate to approximately
ti7108a 0.25 gpm (5 cycles/min.) to increase the heater out-
b. Slowly increase the pressure until the pumps let temperature to match the spray temperature.
start running slowly.
NOTE: Circulating the fluid too quickly without decreas-
c. Run the pumps for a few minutes or until the ing the circulation rate will increase only the hopper tem-
material has reached the desired temperature. perature. Similarly, circulating fluid too slowly will
See Heat Fluid, page 39. increase only the heater outlet temperature.
d. Set the pump valve off.
3A0420ZAC 39
Spray
Spray
4. Adjust the main air regulator (CB) to 30 psi
(0.21 MPa, 2.1 bar) minimum.
CB
NOTE: After the first day of spraying, re-tighten all hose

connection fittings and tighten the throat packing nuts
on both pumps.
1. If heaters are used, turn them on. To adjust the
heater temperature, refer to the Viscon HF or HP
manual for instructions, and the Heat Fluid section,
page 39. Circulate as necessary.
WLD
A B
2. Close the motor air pressure regulator (CB) and
decrease to zero.
5. Remove tip. Disengage the trigger lock and trigger

the gun while holding against a grounded metal pail.
Use a metal pail lid with a hole to dispense through
CB to avoid splashing. Dispense out of the mix hose
until a well mixed coating flows from the gun.
WLD
3. Close the circulation handle (AC) and the solvent

flush valve (AD). Open the dual shutoff handle (AE).
AC
(closed)
TI1950a
AE
(open) TI29649a
AD
6. Engage the trigger lock. Install the tip on the gun.
40 3A0420ZAC
7. Adjust the main pump air regulator (CB) to the nec- 8. Check and record gauge readings frequently during
essary spraying pressure and apply a coating to a operation. A change in gauge readings indicates a
test panel. change in system performance.
NOTE: Run System Verification tests everyday NOTE:

(see page 49).
• A pressure drop occurs during pump stroke change-
over. It should be quick and synchronous.
• Flush the mix manifold as necessary during the
day’s operation.
9. Follow Flush Mixed Material, page 43 when you

are finished spraying or before potlife expires.
NOTE: Mixed material potlife or working time decreases

with increased temperature. Pot life in the hose is much
shorter than the dry time of the coating.
NOTE: Excess pressure increases overspray and
pump wear.
3A0420ZAC 41
B Component Adjustable Fluid Restrictor
B Component Adjustable Fluid Restrictor

The B side restrictor (AJ) reduces momentary “lead/lag” If the mix manifold (AB) is mounted on the machine, you
ratio imbalance of the A and B flow into the static mixer do not need to adjust the restrictor. Leave the restrictor
tubes when the gun opens. The error is caused by dif- stem open two turns minimum from fully closed.
ferences in viscosity, volume, and hose expansion.
To Adjust the Restrictor:
The restrictor is used primarily when the mix manifold is
Adjust the restrictor stem clockwise while spraying until
positioned remotely from the machine with a short mix
you see a slight rise in the B side pressure gauge. The
hose to the spray gun. It can also be used in the ratio
point where the pressure starts to rise is a good adjust-
check procedure.
ment setting.
Unless you are dispensing directly out of the mix mani-

fold and mixer, this is an approximate adjustment.
See the mix manifold manual 3A0590 for more informa-

tion.
Restrictor
Stem
AJ
AB
42 3A0420ZAC
Flush Mixed Material

2. Lift to close the dual shutoff handle (AE).
To avoid fire and explosion, always ground equipment

and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest
possible pressure. Hot solvent may ignite. To avoid fire
AE
and explosion:
• Flush equipment only in a well-ventilated area
• Ensure main power is off and heater is cool before
flushing
• Do not turn on heater until fluid lines are clear of
solvent
WLD
Flush the mix manifold when any of the following situa- 3. Open the solvent pump air valve (DA). Slowly turn
tions occur. the solvent pump air regulator (DB) clockwise to
• breaks in spraying increase air pressure.
• overnight shutdown
• mixed material in system approaching end of potlife
Flush Mix Manifold, Hose, and

Spray Gun
If your system doesn’t include a solvent flush pump, see
Empty and Flush Entire, page 45.
DB
AD
Turn off heaters. Allow heater and heated hoses to cool.
DA
Follow the Pressure Relief Procedure on page 34.
WLD
1. Close the motor air shutoff valve (CA) to turn off the
pump air motor and reduce air pressure. Engage
trigger lock. Remove the spray tip and soak in sol-
vent.
CA
3A0420ZAC 43
4. Open the solvent flush valve (AD) 6. Close the solvent pump air valve (DA). Trigger the
gun to relieve pressure. Close the solvent flush
5. Disengage the trigger lock, hold the gun against a valve (AD) after relieving the pressure.
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 DA
solvent dispenses.
AD
7. Follow Pressure Relief Procedure, page 34.
TI29649a 8. Engage the trigger lock. Disassemble and clean the

spray tip with solvent by hand. Reinstall on the gun.
4)!
44 3A0420ZAC
Empty and Flush Entire System (new system or end of job)
Empty and Flush Entire System

(new system or end of job)
Guidelines
Flush new systems if the coating materials will be con-
taminated by mineral oil.
Flushing will help prevent materials from settling or gell-

ing in the pumps, lines, and valves. Flush the system
To avoid fire and explosion, always ground equipment when any of the following situations occur.
and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest • Anytime the system will not be used for more
possible pressure. Hot solvent may ignite. To avoid fire than one week (depending on materials used)
and explosion: • If the materials used have fillers that will settle
• Flush equipment only in a well-ventilated area
• If using materials that are moisture sensitive
• Ensure main power is off and heater is cool before
flushing • Before servicing
• Do not turn on heater until fluid lines are clear of • If the machine is going into storage, replace the
solvent flush solvent with light oil. Never leave the
equipment empty of any fluid.
NOTE:
• If the system includes heaters and heated hose,
turn them off and allow to cool before flushing. Do
not turn on the heaters until the fluid lines are clear
of solvent.
• Cover fluid containers and use the lowest possible

pressure when flushing to avoid splashing.
• Before color change or shutdown for storage, circu-

late the solvent at a higher flow rate and for a longer
time. Change the solvent when it gets dirty.
• To only flush the fluid manifold, see Flush Mix Man-

ifold, Hose, and Spray Gun, page 43.
• If the machine is inoperable, use drain plugs on the

pump inlet fittings.
3A0420ZAC 45
Empty System Procedure 4. Move recirculation lines (U) to separate fluid con-
tainers to pump remaining fluid out of the system.
1. Follow Prime Empty System, page 35 and Flush
Mix Manifold, Hose, and Spray Gun, page 43, as
required.
8
2. Engage the trigger lock.
TI1949a
3. XP Systems: Turn the main pump air regulator

(CB) fully counter-clockwise to shut off. WLD
5. Lower to open the circulation handle (AC) and

increase the motor air pressure regulator (CB)
CB
pressure to 20 psi (138 kPa, 1.38 bar).
CB
CA
XP-h Systems: Set pump valve on.
B
A
AC
WLD
6. Open the motor air shutoff valve (CA).
NOTE: If the system does not start with static pres-

sure, increase the air pressure by 5 psi (35 kPa,
0.35 bar) increments. To avoid splashing, do not
exceed 35 psi (241 kPa, 2.4 bar).
7. Run the pumps until the A and B hoppers (J) are

empty. Salvage the material in separate, clean con-
tainers.
46 3A0420ZAC
Flush System Procedure 6. Increase the motor air pressure regulator to dis-
pense fresh solvent from the hoppers through the
1. For XP Systems: Close the main air shutoff valve mix manifold valves and out the gun.
(CA).
7. Turn off the air motor.
8. Lift to close the dual shutoff handle (AE).
CA
AE
For XP-h Systems: Set pump valve to off.
ti7108a ti7108a
WLD
2. Wipe the hoppers (J) clean, then add solvent to
9. Remove pump fluid filters, if installed, and soak in
each. Move the circulation lines (U) to waste con-
solvent. Clean and replace the filter cap. Always
tainers and push out the dirty fluids.
replace the filter o-rings. See Xtreme pump manual
3. Move the recirculation lines (U) back to the hoppers. 311762.
Continue recirculating until the system is thoroughly
10. Fill the A and B pump packing nuts with TSL. Also,
flushed.
always leave some type of fluid, such as solvent or
4. Lift to close the circulation handle (AC) and lower to oil, in the system to prevent scale build up. This
open the dual shutoff handle (AE). build up can flake off later. Do not use water.
NOTE:
• If machine is set up with a remote mix manifold, the
A and B hose can be disconnected from the mix
manifold, and secured back to each hopper for cir-
AC culation of flush solvent.
(closed)
• Change the flush solvent at least once until it circu-
lates clean.
• Always keep the A side and B side flush solvent
AE containers separate to avoid cross-contamination.
(open)
WLD
5. Open the motor air shutoff valve. Increase the air

regulator pressure to 20 psi (1.9 bar).
3A0420ZAC 47
Park
Park Shutdown
1. Lower to open the circulation handle (AC) and 1. Flush mix manifold, hoses, and gun. See Flush Mix
adjust the air regulator (CB) so that the pump runs Manifold, Hose, and Spray Gun, page 43.
slowly.
2. Close the main air shutoff valve (CA).
CB
B
A AC
CA
WLD
WLD
2. Lift to close the circulation handle (AC) when the 3. Close solvent air valve and turn solvent air regulator
pump is at the bottom of the stroke. fully counterclockwise. Trigger gun to relieve any
residual pressure.
WLD
AC
0
STOP
WLD
3. Close the motor air valve (CA) and turn the air regu-
lator (CB) counterclockwise. Lower to open the cir- 4. Close solvent fluid valve and lower re-circulation
culation handle (AC). handle (AC).
CB
$&
AC
CA WLD
WLD
48 3A0420ZAC
System Verification
System Verification
Graco recommends running the following tests daily. Spots that take longer to cure indicate insufficient pump
loading, leakage, or lead/lag errors at a remote mix
Check for Normal Operation manifold.
Every time you start spraying:

Appearance Test
• Watch the fluid gauges (AF). A pressure drop Spray material onto foil. Look for variations in color,
occurs during pump stroke changeover. It should be gloss, or texture that may indicate improperly catalyzed
quick and synchronous. material.
• Stop the pumps on the upstroke. Check that both
gauges hold pressure for at least 20 seconds. See Monitor Fluid Supply
Pump Troubleshooting on page 52.
NOTE: To prevent pumping air into the system, which
If one gauge drops, the others will rise. causes incorrect proportioning, never allow the feed
pump or solvent pump containers to run dry.
• Stop the pumps on the down-stroke. Check that all
gauges hold pressure. An empty pump will quickly accelerate to a high speed,
and may damage itself and the other displacement
• If using feed pumps, check that both feed pumps pump because it causes a pressure rise in the other
run during the proportioner upstroke. pump. If a supply container runs dry, stop the pump
immediately, refill the container, and prime the system.
Mix and Integration Tests Be sure to eliminate all air from the system.
Use the following tests to check for proper mix and inte-
gration. Check Pot Life
Check the fluid manufacturer's instructions for fluid pot
Butterfly Test life at your fluid temperature. Flush mixed fluid out of the
mix manifold, hose, and gun before pot life time expires,
or before a rise in viscosity affects the spray pattern.
Ratio Check
At low pressure, and with the spray tip reversed, dis-
Check the ratio at the mix manifold after any changes to
pense a 1/2 in. (12.7 mm) bead of material onto foil until
the proportioning system. Use Ratio Check Kit 24F375
multiple changeovers of each pump have occurred. Fold
to check the ratio at the mix manifold. See manual ratio
the sheet of foil over the fluid then peel it back and look
check kit manual for instructions and parts.
for unmixed material (appears marble-like), or color
changes.
To prevent an inaccurate ratio check when feed pumps
are used in your system, the feed pressure cannot be
Curing Test
more than a maximum of 25% of the proportioner outlet
Spray a single continuous pattern on foil at typical pres- pressure. High feed pressure can float the proportioner
sure setting, flow rate, and tip size until multiple change- pump check balls, resulting in an inaccurate ratio check.
overs of each pump have occurred. Trigger and There must be back pressure on both sides of the mix
de-trigger at typical intervals for the application. Do not manifold when checking the ratio.
overlap or cross over your spray pattern.
Check curing at various time intervals, listed on the

material data sheet. For example, check for dry to touch
by running your finger along the test pattern’s entire
length at the time listed on the data sheet.
3A0420ZAC 49
Maintenance
Maintenance
Hose Electrical Resistance 3. Turn off all heaters and allow equipment to cool.
Check electrical resistance of hoses regularly. If total 4. Flush mixed material. See Flush Mixed Material,
resistance to ground exceeds 29 megohms, replace page 43.
hose immediately.
5. Perform the Pressure Relief Procedure on page
34.
Filters 6. Perform Park and Shutdown procedures, page 48.
Once a week check, clean, and replace (if needed) the Turn off all power.
following filters.
7. Clean the external surfaces only using a rag soaked
• Both pump filters; see lower manual for instructions. in solvent that is compatible with the spray material
and surfaces being cleaned.
• Spray gun handle filter; see spray gun manual.
8. Allow enough time for the solvent to dry before
using the system.
Seals
Once a week, check and tighten throat seals on both
pumps. See table for torque specifications. Be sure to Change the Mix Ratio
follow the Pressure Relief Procedure on page 34, prior
In order to change the mix ratio, one or both pumps
to tightening seals. There must be zero pressure on the
need to be replaced, the air motor needs to be re-posi-
pumps when adjusting.
tioned, and the over pressure relief valves may need to
be changed.
Pump Size Torque Specification
All 25-30 ft-lb (34-41 N•m) 1. Check the Parts Varying by Pump Package table
on page 72 for the correct pump sizes.
2. Remove and replace pump. See Remove Dis-

Cleaning Procedure placement Pump page 53.
3. Adjust the position of the air motor. See Motor

Position page 30.
4. If changing from one type of XP system to

another (for example - changing from XP50 to
XP70 or from XP70 to XP50): Remove the existing
over pressure relief valves (302) and install the cor-
1. Ensure all equipment is grounded. See Grounding, rect valves for the new system type. See Replace
page 28. Over Pressure Relief Valves on page 56.
2. Ensure the area where the system will be cleaned is 5. Change the air pressure relief valve (CG) as
well ventilated and remove all ignition sources. required, depending on the ratio.
50 3A0420ZAC
Troubleshooting
Troubleshooting
 Fluid ratio will be wrong.
 Purge all air from system before proportioning
fluids.
Problem Cause Solution

System stops or will not start. Air pressure or volume too low. Increase; check air compressor.
Closed or restricted air line or air Open or clean.
valve.
Fluid valves closed. Open.
Clogged fluid hose. Replace.
Air motor worn or damaged. Repair air motor; see 311238.
Displacement pump stuck. Repair pump; see 311762.
System speeds up or runs erratically. Fluid containers are empty. Check often; keep filled.
Air in fluid lines. Purge; check connections.
Displacement pump parts worn or Repair pump; see 311762.
damaged.
Pump operates, but resin output Dirty, worn, or damaged resin pump Clean, repair pump; see 311762.
pressure drops on upstroke. piston valve or piston packings.
Pump operates, but resin output Dirty, worn, or damaged resin pump Clean, repair pump; see 311762.
pressure drops on down-stroke. intake valve.
Pump operates, but resin output Hardener output restriction. Clean, unplug hardener side. Open
pressure drops on both strokes. manifold restrictor.
Fluid supply low. Refill or change container.
Pump operates, but hardener output Dirty, worn, or damaged hardener Clean, repair pump; see 311762.
pressure drops on upstroke. pump piston valve or piston pack-
ings.
Pump operates, but hardener output Dirty, worn, or damaged hardener Clean, repair pump; see 311762.
pressure drops on down-stroke. pump intake valve.
Pump operates, but hardener output Resin output restriction. Clean, unplug resin side.
pressure drops on both strokes. Fluid supply low. Refill or change container.
Fluid leak in packing nut. Loose packing nut or worn throat Tighten; replace; see 311762.
packings.
Fluid leak under packing nut Packing cartridge o-ring. Replace o-ring; see 311762
Relief valve (AM) leaks back to sup- Relief valve is dirty or damaged. Replace over pressure relief
ply, opens too soon, or will not close. valve (302)
No pressure on hardener side; fluid Overpressure rupture disk blown. Determine cause of overpressuriza-
leaking from hardener pump outlet tion and correct. Replace rupture disk
rupture disc fitting. assembly 258962 (see page 72) and
over pressure relief valve (302).
Pressure and flow surges on Feed pressure too high. Every 1 psi Reduce feed pressure. See Techni-
upstroke. of feed pressure adds 2 psi during cal Specifications, page 91.
upstroke.
3A0420ZAC 51
Troubleshooting
Problem Cause Solution

Fluid outlet pressure gauges split Not fully loading one side on Increase feed pressure on side that
only at the top changeover (if one upstroke. dropped.
gauge drops the other will rise).
Increase feed hose size.
Clean inlet strainer or hopper screen.

Air mixed in fluid from excessive agi- Flush and add new fluid.
tation or circulation.
Pump Troubleshooting
This chart uses proportioning fluid gauges to determine pump malfunctions. Observe the gauge readings during the
stroke direction indicated by the bold arrow, and immediately after closing the gun or mix manifold. Refer to other
manuals to troubleshoot individual components.
TROUBLE AREA: TROUBLE AREA:
Resin Pump Leakage Hardener Pump Leakage
1. Throat packing 1. Throat packing
2. Piston packing 2. Piston packing
3. Piston ball check 3. Piston ball check
Resin Hardener
Pump Pump Resin Hardener
Pump Pump
Falling Rising
Rising Falling
r_258914_3a0420a_11a r_258914_3a0420a_11a
TROUBLE AREA: TROUBLE AREA:

Resin Pump Leakage Hardener Pump Leakage
1. Throat packing 1. Throat packing
2. Intake ball check 2. Intake ball check
Resin Hardener Resin Hardener

Pump Pump Pump Pump
Falling Rising Rising Falling

r_258914_3a0420a_10a r_258914_3a0420a_10a
52 3A0420ZAC
Repair
Repair
3. If feed pumps are installed, close the inlet ball valve.
Remove inlet union (61).
4. Remove the spring clamp (130) and coupling (119

To avoid serious injury due to the pump assembly or 120).
falling, secure a hoist to the lift ring.
Follow Park procedure on page 48, which includes

flushing, if service time may exceed pot life time, before
servicing fluid components, and before transporting sys-
tem to a service area.
106
Pump Assembly
135 105
The displacement pumps and air motor may be
removed and serviced separately or the entire pump
130
and motor assembly can be removed with a hoist.
119
Remove Pump Assembly
1. Stop the pumps near the bottom of their stroke. Fol-
low Park, page 48.
2. Disconnect all hoses from the pump assembly.

117
3. If hoppers are installed, disconnect the hopper fluid
lines from the pump fluid inlet. See Hoppers, page 118
58.
NOTE: The hopper and hopper bracket do not need 108

to be removed from the cart.
r_258914_3a0420a_5a
4. Remove screws (6) and washers (5) under the tie

plate (101). 5. Use a wrench to hold the tie rod (105, 106) flats to
keep the rods from turning. Unscrew the nuts (108)
5. Use hoist to remove the pump assembly by the lift from the tie rods and carefully remove the displace-
ring and carefully lift out of cart (1). ment pump (117 or 118) and lower straps (135).
Remove Displacement Pump 6. Refer to the Xtreme Displacement Pump manual to

service or repair the displacement pump.
1. Follow Park, page 48.
7. Follow the steps in reverse order to reinstall the dis-
2. If hoppers are installed, remove the hopper and placement pump.
hopper bracket from the cart. See Hoppers, page
58. Torque nuts (108) to 50-60 ft-lb (68-81 N•m).
3A0420ZAC 53
Repair
Remove Motor 7. Use a hoist to remove the air motor by the lift ring.
1. Stop the pumps near the bottom of their stroke. Fol- 8. Refer to the air motor manual to service or repair the
low Park, page 60. air motor.
2. Disconnect the air line from the air motor (103). 9. Follow the steps in reverse order to reinstall the air
motor.
3. Remove the air motor rod cover (121) and pump
guards (122). Position air motor for correct mix ratio. See Motor Posi-
tion on page 30 for instructions. Torque nuts (108) to
Air Motor shown 50-60 ft-lb (68-81 N•m).
103
121 Air Controls

For XP systems only. See FIG. 7 on page 55.
Replace Air Control Assembly

122
1. Close the main air shutoff valve on the air supply
r_258914_3a0420a_7a line and on the system. Depressurize the air line.
2. Disconnect the air motor air lines and system air

4. Use a wrench to hold the tie rod (102) flats to keep line.
the rods from turning. Unscrew the nuts (108) and
washers (107) from the tie rods. 3. Remove the nut (8) and washer (5). Remove the
bottom air control manifold assembly from the cart.
Air Motor shown
lift ring
4. Loosen the upper air control assembly from the air
motor.
5. Follow the steps in reverse order to reinstall the new

air control assembly.
102 Replace Air Filter Element

1. Close the main air shutoff valve on the air supply
line and on the system. Depressurize the air line.
104
111 2. Unscrew the serrated ring on filter bowl (210).
r_258914_3a0420a_8a
3. Remove and replace the filter element (210a). See

Air Controls, 258983, page 73.
107
108 Replace System Air Regulator
109 1. Close the main air shutoff valve on the air supply
line and on the system.
5. Place a wrench on adapter rod (104). Use tool (70)
to loosen the serrated yoke nut (109) that holds the 2. Disconnect air motor air lines and system air line.
air motor (103) above the yoke (111).
3. Remove the regulator assembly (201) and replace
6. Face the front of the machine and slide the air motor with new regulator. See Air Controls, 258983,
(103) to the opening in the yoke (111). page 73.
4. Follow the steps in reverse order to reassemble.
54 3A0420ZAC
Repair
For XP systems only.
201
206
203
209
214
206
207
Air Flow
216 214
215
208
213
204
Air Flow 202

211 205
209
210
5, 8
r_571101_3A0420A_1a-2
FIG. 7: Air Control Assembly 258983
3A0420ZAC 55
Repair
Mix Manifold Assembly 5. Remove the two screws (37) and fluid circulation
manifold (35) from the cart (1).
1. Follow the Park procedure and Shutdown proce-
1
dure on page 48.
2. Disconnect the fluid hose (25) and the flush hose 35

from the mix manifold (36).
3. Loosen the union fittings (306) that connect to the 37

mix manifold adapter fittings.
4. Remove the mix manifold assembly (36). r_571101_3a0420a_39a
5. See mix manifold manual for service and repair

instructions. Replace Over Pressure Relief Valves
dure on page 48.
2. Ensure handle (312) is in the down position.

306 Remove the screws (313), jam nut (304), handles
(311), handle rod (312), clips (318), and
springs (320).
311
312
313
302
36
311
313
304
302
318 320
302
r_571101_3a0420a_38a 304
320
Fluid Circulation Manifold with r_258988_3a0420a_2b
318
Over Pressure Relief Valves 3. Unscrew both over pressure relief valves (302) from
the manifold.
dure on page 48. NOTE: The correct over pressure relief valve must be
used on all systems. Choose the correct color coded
2. Disconnect all fluid hoses from the fluid circulation
valve from the chart on page 57.
manifold (35).
3. Remove the mix manifold if it is assembled to the 4. Apply blue threadlock to new over pressure relief
fluid circulation manifold. See Mix Manifold valves (302) and install in the manifold. Torque to
Assembly (page 56) for instructions. 28-32 ft-lb (38-43 N•m).
4. Loosen the two screws (37) that secure the manifold 5. Place a spring (320) over each valve stem. Place a
(35) to the cart (1). clip (318) in each valve stem groove to retain the
springs.
56 3A0420ZAC
Repair
6. Slide handle (311) onto valve stem and rotate 11. Install two screws (313) in handles (311).
approximately 90° until you feel it fully lock against
the seat valve. Repeat for opposite side. 12. Check operation of the handle and valves.
7. Remove handle then place handle (311) on valve 13. Operate the handle in and out of the spray and cir-
stem (302) at the vertical, or near vertical, position. culate positions.
8. Apply blue threadlock on the nut (304) threads and 14. Check for clearance with fittings.
tighten the handle against the spring (320) and
clip (318). Torque to 70-80 in-lb (7.9-9 N•m). NOTE:
• Both valves should settle firmly into the spray posi-
9. Place the rod (312) and the second handle (311) on tion inward against the seats in the valve.
second valve stem aligned with the opposite handle.
• Both valve stems should rotate out to their most
10. Repeat step 9. extended positions when the handle is pulled down
to the circulate position.
Fluid Circulation Manifold Replacement Guide
Colored Valve Sleeve
ti19169a
ti19168a
Circulation Relief Target Opening

Manifold (35) Valve (302) Valve Sleeve Pressure
Part No. Part No. Color psi (MPa, bar) Use with:
All XP35 models,
262784 262808 Purple 5300 (37, 365) XP-h models 284101, 284251,
284201, 284301, 284401
All XP50 models,
262783 262809 Gold 7100 (49, 490) XP-h models 284102,
284202, 284252, 284302, 284402
All XP70 models,
262806 262520 Silver 9250 (64, 638) XP-h models 284103,
284203, 284253, 284303, 284403
NOTE: Original XP70 valves did not include a silver valve sleeve. When replacing these original valves, replace with
the current valves that have the silver valve sleeve.
3A0420ZAC 57
Repair
Hoppers 6. Lift the hopper off of the mounting bracket.
1. If material is in the hopper, pump out the remaining 7. Repeat for second hopper.
material.
2. If the pump has failed: Solvent Pump

a. Place a waste container beneath the plug on fit- 1. Follow Pressure Relief Procedure, page 34.
ting (61). Remove the plug.
2. Disconnect the fluid line and air lines from the sol-
b. Drain all material from hopper into the waste vent pump.
container.
3. Loosen the four screws that attach the solvent pump
c. Install plug after material is no longer draining
to the cart (1). Lift and pull pump from the slots.
from fitting (61).
1
r_571101_3a0420a_41a
plug 61
4. Loosen fitting (61) and disconnect hopper from

pump.
5. Remove the recirculation line from the hopper and

place in a waste container.
screw
4. Refer to the Merkur Pump Assembly manual to ser-

vice or repair the solvent pump.
5. Follow the steps in reverse order to reinstall the sol-

vent pump.
U
r_571101_3a0420a_18a
58 3A0420ZAC
Repair
Fluid Heaters
Wiring for heaters is not provided, other than with com- 4. Reconnect the fluid lines and electrical wiring.
plete systems. See the Viscon HP or Viscon HF heater
manual for wiring, repair, and parts information. Replace
1. Follow steps 1 through 2 in the Fluid Heaters Ser-
Service and Repair
vice and Repair section.
2. Loosen the four mounting screws, lock washers,
2. Disconnect the fluid lines and electrical wiring from and plain washers on back of the heater. Slide the
the fluid heater. heater up and remove from the cart.
3. Refer to the Viscon HP or Viscon HF heater manual 3. Replace the heater. Follow the steps in reverse
to service or repair. Refer to the heater adapter kit order to install a new heater.
manual 406861 for installation instructions.
r_571101_3a0420a_42a
WLD
HP Heater Shown HF Heater Shown
3A0420ZAC 59
Parts
Parts
System Common Parts

Label No.
16F359 C
Modifying this machine or adding

Non-approved accessories 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 lajout
daccessoires non approuv és par les vides de
la zone dangereuse approbations.

%

$

WLD
60 3A0420ZAC
Parts
Parts Common to All Systems
Ref Part Description Qty Ref Part Description Qty

1 258913 CART, weldment 1 29 150287 COUPLING 1
2 262476 AXLE 1 32 162024 COUPLING 2
3 111841 WASHER, plain 5/8 2 36 262807 MANIFOLD, mix, 1/2 valves 1
5 100133 WASHER, lock, 3/8 7 37 106212 SCREW, cap, hex head 2
6 100101 SCREW, cap, hex head 4 38 116139 GRIP, handle 2
7 113362 WHEEL, semi-pneumatic 2 47* 206995 FLUID, TSL, 1 qt. 1
8 154628 WASHER 2 48 101566 NUT, lock 2
9 113436 RING, retaining 2 49 15U654 LABEL, identification, A/B 1
10 124410 BEARING, sleeve, 1.00 x 1.25 x 1 50 555357 SCREW 4
1.5 52 124293 BOLT, u-bolt, 3/8-16, 1.0 dia. 1
11 124664 WASHER, 1 in. ID, stainless 2 53 124259 BRAKE, plunger clamp 1
steel 54 124291 PIN, spring 2
12 15A913 AXLE 1 58 116704 ADAPTER, 9/16-18 JIC x 1/4 npt 2
13 191824 WASHER, space 4 59 15V421 TUBE, recirculation 2
14 113807 WHEEL, flat free, urethane 2 67* 16E336 GUIDE, quick start 1
15 258982 HANDLE, cart 1 68 114958 STRAP, tie 10
16 101242 RING, retaining, ext. 2 69* 16F615 TOOL, wrench, Xtreme 1
17 258983 MODULE, air controls, inlet 1 70 16F359 LABEL, warning, fire and explo- 1
18 100131 NUT, full hex 3 sion hazard
19 16F206 LABEL, solvent 1 71 16F536 LABEL, arrow 2
20 512519 MIXER, 1/2-12 element 3 89* 16G819 TOOL, wrench, Xtreme, filter 1
21 111218 CAP, tube, square 4 92* 126786 TOOL, wrench, restrictor valve 1
24 H75003 HOSE, coupled, 7250 psi, 2
0.50 ID, 3 ft
26 15B729 COUPLING 1  Replacement Danger and Warning labels, tags, and
27 262478 HOUSING, mixer 3 cards are available at no cost.
28* 248927 KIT, mixer element, 25 pack 1 * Part is shipped loose.
3A0420ZAC 61
Parts
Parts Varying by Model

WLD

62 3A0420ZAC
Parts
Parts Varying by Model (continued)

+$=/2&$7,21
+($7(5

WLD

TSL

3A0420ZAC 63
Parts Varying By Model - XP35 Systems
64
Parts
Quantity (by system)
281101
281102
281103
282104
574105
574106
574107
281201
281202
281203
281204
574205
574206
574207
262804
281252
281253
281254
574255
574256
574257
281301
281302
281303
281304
574305
574306
574307
281401
281402
281403
281404
574405
574406
574407
Ref. Part Description
4 281100 PUMP PACKAGE, fixed ratio, 1.0:1 1 1 1 1 1 1 1
281200 PUMP PACKAGE, fixed ratio, 2.0:1 1 1 1 1 1 1 1
22 158491 FITTING, nipple 4 4 6 6 6 6 6 4 4 6 6 6 6 6 4 4 6 6 6 6 6 4 4 6 6 6 6 6 4 4 6 6 6 6 6
23 15M987 FITTING, elbow, 60 degree 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4
25 H43825 HOSE, 4500 psi, 3/8 x 25 ft. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
30 H52510 HOSE, cpld, 4500 psi, .25 x 10 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
31 XTR502 GUN, XTR5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
35 262784 MANIFOLD, recirculation, 1/2 valves 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
41 158683 FITTING, elbow, 90 degree 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4
51 124450 CLAMP, spring, constant-tension 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
55 24E872 BRACKET, hopper 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
56 262479 HOPPER, blue 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
57 262480 HOPPER, green 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
60 H52506 HOSE, coupled, 5600 psi, 0.25 ID, 6 ft 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
H52510 HOSE, coupled, 5600 psi, 0.25 ID, 10 ft 2 2 2 2 2 2 2 2 2 2
61 16D376 FITTING, swivel, 1-1/4, with plug 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
62 111192 SCREW, cap flange head 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
64 103347 VALVE, safety, 100 psi 1 1 1 1 1 1 1
113498 VALVE, safety, 110 psi 1 1 1 1 1 1 1
114055 VALVE, safety, 105 psi 1 1 1 1 1 1 1 1 1 1 1 1 1 1
16M190 VALVE, safety, 95 psi 1 1 1 1 1 1 1
65 262482 STRAINER, hopper, 7 gallon 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
66 15T468 LABEL, warning 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
72 262392 PUMP, solvent, 6.0 in., 50 cc, std 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
73 104984 FITTING, tee, pipe 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
74 156971 FITTING, nipple, short 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
75 H42503 HOSE, cpld, 4500 psi, .25 ID, 3 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
76 214037 VALVE, ball 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
77 205447 COUPLING, hose 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
78 061132 HOSE, nylon (4 ft) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
79 24F126 MODULE, air controls, solvent 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
80 16F537 HOSE, coupled, 6 ft, 1/4 npsm, 5/16 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
81 15B772 HOSE, air, 18 in. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
3A0420ZAC
83 H75004 HOSE, (heater to manifold) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

84 166590 FITTING, elbow, elec 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
85 245863 HEATER, XP, haz, tstat 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
245869 HEATER, XP, non-haz, tstat 2 2 2 2 2 2 2 2 2 2
65
Parts
281101
281102
281103
282104
574105
574106
574107
281201
281202
281203
281204
574205
574206
574207
262804
281252
281253
281254
574255
574256
574257
281301
281302
281303
281304
574305
574306
574307
281401
281402
281403
281404
574405
574406
574407
90 16J688 PLUG, hole, gauge 1 1 1 1 1 1 1 1 1 1
93 273096 KIT, junction box 1 1 1 1 1 1 1 1 1 1
94* 17P846 BRACKET, painted, junction box 1 1 1 1 1 1 1 1 1 1
95 273093 PUMP, XPhf, htd-hose, re-circ 1 1 1 1 1 1 1 1 1 1
96 17P092 PLATE, XPhf, re-circ, painted 1 1 1 1 1 1 1 1 1 1
97 110755 WASHER, plain 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6
98 100016 WASHER, lock 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6
99 104429 SCREW, cap hex hd 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6
100 17N936 MONITOR, PressureTrak, XPhf 1 1 1 1 1 1 1 1 1 1
101 273094 HEATER, hose, hazardous loc. 1 1 1 1 1 1 1 1 1 1 1
273095 HEATER, hose, non-hazardous loc. 1 1 1 1 1 1 1 1
102 248208 HOSE, cpld, 4 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
103 17N598 HARNESS, SW3 to fluid A 1 1 1 1 1 1 1 1 1 1
104 17N599 HARNESS, SW4 to fluid B 1 1 1 1 1 1 1 1 1 1
105* 113796 SCREW, flanged, hex hd 8 8 8 8 8 8 8 8 8 8
106* 115942 NUT, hex, flange head 2 2 2 2 2 2 2 2 2 2
107 17P594 FITTING, assy, hose coupler, split 1 1 1 1 1 1 1 1 1 1
108 17S051 FITTING, assy, hose nipple, split 1 1 1 1 1 1 1 1 1 1
109 24Z934 HEATER BLOCK, remote
1 1 1 1 1 1 1 1 1 1
manifold
110 113974 SCREW, thrd forming (10-24) 1 1 1 1 1 1 1 1 1 1
 Replacement Danger and Warning labels, tags, and cards are available at no cost.
* Included in Kit 273096
3A0420ZAC
66
Parts
282101
282102
282103
282104
575105
575106
575107
282151
282152
282153
282154
575155
575156
575157
282201
282202
282203
282204
575205
575206
575207
282251
282252
282253
282254
575255
575256
575257
282301
282302
282303
282304
575305
575306
575307
282331
282332
282333
282334
282401
282402
282403
282404
575405
575406
575407
4 282100 PUMP PACKAGE, fixed ratio,
1 1 1 1 1 1 1
1.0:1
282150 PUMP PACKAGE, fixed ratio,
1 1 1 1 1 1 1
1.5:1
1 1 1 1 1 1 1
2.0:1
1 1 1 1 1 1 1
2.5:1
1 1 1 1 1 1 1
3.0:1
1 1 1 1
3.3:1
1 1 1 1 1 1 1
4.0:1
22 158491 FITTING, nipple 4 4 6 6 6 6 6 4 4 6 6 6 6 6 4 4 6 6 6 6 6 4 4 6 6 6 6 6 4 4 6 6 6 6 6 4 4 6 6 4 4 6 6 6 6 6
23 15M987 FITTING, elbow, 60 degree 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 2 2 4 4 4 4 4
25 H53825 HOSE, 5600 psi, 3/8 x 25 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
30 H52510 HOSE, cpld, 4500 psi, .25 x 10 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
31 XTR502 GUN, XTR5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
35 262783 MANIFOLD, recirculation, 1/2
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
valves
41 158683 FITTING, elbow, 90 degree 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 2 2 4 4 4 4 4
51 124450 CLAMP, spring, constant-tension 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
55 24E872 BRACKET, hopper 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
56 262479 HOPPER, blue 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
57 262480 HOPPER, green 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
60 H52506 HOSE, coupled, 5600 psi, 0.25
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
ID, 6 ft
H52510 HOSE, coupled, 5600 psi, 0.25
2 2 2 2 2 2 2 2 2 2 2 2 2 2
ID, 10 ft
61 16D376 FITTING, swivel, 1-1/4, with plug 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
62 111192 SCREW, cap flange head 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
64 103347 VALVE, safety, 100 psi 1 1 1 1 1 1 1 1 1 1 1
113498 VALVE, safety, 110 psi 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
114055 VALVE, safety, 105 psi 1 1 1 1 1 1 1
65 262482 STRAINER, hopper, 7 gallon 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
66 15T468 LABEL, warning 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
72 262392 PUMP, solvent, 6.0 in., 50 cc, std 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
3A0420ZAC
73 104984 FITTING, tee, pipe 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

74 156971 FITTING, nipple, short 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
75 H42503 HOSE, cpld, 4500 psi, .25 ID, 3 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
76 214037 VALVE, ball 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
67
Parts
282101
282102
282103
282104
575105
575106
575107
282151
282152
282153
282154
575155
575156
575157
282201
282202
282203
282204
575205
575206
575207
282251
282252
282253
282254
575255
575256
575257
282301
282302
282303
282304
575305
575306
575307
282331
282332
282333
282334
282401
282402
282403
282404
575405
575406
575407
77 205447 COUPLING, hose 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
78 061132 HOSE, nylon (4 ft) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
79 24F126 MODULE, air controls, solvent 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
80 16F537 HOSE, coupled, 6 ft, 1/4 npsm,
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
5/16
81 15B772 HOSE, air, 18 in. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
83 H75004 HOSE, (heater to manifold) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 2 2 2 2 2
84 166590 FITTING, elbow, elec 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 2 2 2
85 245863 HEATER, XP, haz, tstat 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 2 2 2
245869 HEATER, XP, non-haz, tstat 2 2 2 2 2 2 2 2 2 2 2 2
90 16J688 PLUG, hole, gauge 1 1 1 1 1 1 1 1 1 1 1 1 1 1
93 273096 KIT, junction box 1 1 1 1 1 1 1 1 1 1 1 1
94* 17P846 BRACKET, painted, junction box 1 1 1 1 1 1 1 1 1 1 1 1
95 273093 PUMP, XPhf, htd-hose, re-circ 1 1 1 1 1 1 1 1 1 1 1 1
96 17P092 PLATE, XPhf, re-circ, painted 1 1 1 1 1 1 1 1 1 1 1 1
97 110755 WASHER, plain 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6
98 100016 WASHER, lock 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6
99 104429 SCREW, cap hex hd 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6
100 17N936 MONITOR, PressureTrak, XPhf 1 1 1 1 1 1 1 1 1 1 1 1
101 273094 HEATER, hose, hazardous loc. 1 1 1 1 1 1 1 1 1 1 1 1
273095 HEATER, hose, non-hazardous
1 1 1 1 1 1 1 1 1
loc.
102 248208 HOSE, cpld, 4 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
103 17N598 HARNESS, SW3 to fluid A 1 1 1 1 1 1 1 1 1 1 1 1
104 17N599 HARNESS, SW4 to fluid B 1 1 1 1 1 1 1 1 1 1 1 1
105* 113796 SCREW, flanged, hex hd 8 8 8 8 8 8 8 8 8 8 8 8
106* 115942 NUT, hex, flange head 2 2 2 2 2 2 2 2 2 2 2 2
107 17P594 FITTING, assy, hose coupler, split 1 1 1 1 1 1 1 1 1 1 1 1
108 17S051 FITTING, assy, hose nipple, split 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1
manifold
110 113974 SCREW, thrd forming (10-24) 1 1 1 1 1 1 1 1 1 1 1 1
3A0420ZAC
68
Parts
571101
571102
571103
571104
576105
576106
576107
571151
571152
571153
571154
576155
576156
576157
571201
571202
571203
571204
576205
576206
576207
571251
571252
571253
571254
576255
576256
576257
571301
571302
571303
571304
576305
576306
576307
571401
571402
571403
571404
576405
576406
576407
4 571100 PUMP PACKAGE, fixed ratio, 1.0:1 1 1 1 1 1 1 1
22 158491 FITTING, nipple 4 4 6 6 6 6 6 4 4 6 6 6 6 6 4 4 6 6 6 6 6 4 4 6 6 6 6 6 4 4 6 6 6 6 6 4 4 6 6 6 6 6
23 15M987 FITTING, elbow, 60 degree 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4
25 H73825 HOSE, 7250 psi, 3/8 x 25 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
30 H52510 HOSE, cpld, 4500 psi, .25 x 10 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
31 XTR502 GUN, XTR5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
35 262806 MANIFOLD, recirculation, 1/2 valves 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
41 158683 FITTING, elbow, 90 degree 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4 2 2 4 4 4 4 4
51 124450 CLAMP, spring, constant-tension 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
55 24E872 BRACKET, hopper 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
56 262479 HOPPER, blue 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
57 262480 HOPPER, green 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
60 H52506 HOSE, coupled, 5600 psi, 0.25 ID, 6 ft 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
H52510 HOSE, coupled, 5600 psi, 0.25 ID, 10 ft 2 2 2 2 2 2 2 2 2 2 2 2
61 16D376 FITTING, swivel, 1-1/4, with plug 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
62 111192 SCREW, cap flange head 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
64 113498 VALVE, safety, 110 psi 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
116643 VALVE, safety, 105 psi 1 1 1 1 1 1 1
65 262482 STRAINER, hopper, 7 gallon 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
66 15T468 LABEL, warning 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
72 262392 PUMP, solvent, 6.0 in., 50 cc, std 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
73 104984 FITTING, tee, pipe 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
74 156971 FITTING, nipple, short 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
75 H42503 HOSE, cpld, 4500 psi, .25 ID, 3 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
76 214037 VALVE, ball 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
77 205447 COUPLING, hose 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
78 061132 HOSE, nylon (4 ft) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
79 24F126 MODULE, air controls, solvent 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
80 16F537 HOSE, coupled, 6 ft, 1/4 npsm, 5/16 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
81 15B772 HOSE, air, 18 in. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
83 H75004 HOSE, (heater to manifold) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
3A0420ZAC
84 166590 FITTING, elbow, elec 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

85 245863 HEATER, XP, haz, tstat 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
245869 HEATER, XP, non-haz, tstat 2 2 2 2 2 2 2 2 2 2 2 2
90 16J688 PLUG, hole, gauge 1 1 1 1 1 1 1 1 1 1 1 1
69
Parts
571101
571102
571103
571104
576105
576106
576107
571151
571152
571153
571154
576155
576156
576157
571201
571202
571203
571204
576205
576206
576207
571251
571252
571253
571254
576255
576256
576257
571301
571302
571303
571304
576305
576306
576307
571401
571402
571403
571404
576405
576406
576407
93 273096 KIT, junction box 1 1 1 1 1 1 1 1 1 1 1 1
94* 17P846 BRACKET, painted, junction box 1 1 1 1 1 1 1 1 1 1 1 1
95 273093 PUMP, XPhf, htd-hose, re-circ 1 1 1 1 1 1 1 1 1 1 1 1
96 17P092 PLATE, XPhf, re-circ, painted 1 1 1 1 1 1 1 1 1 1 1 1
97 110755 WASHER, plain 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6
98 100016 WASHER, lock 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6
99 104429 SCREW, cap hex hd 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6 2 2 2 2 2 6 6
100 17N936 MONITOR, PressureTrak, XPhf 1 1 1 1 1 1 1 1 1 1 1 1
101 273094 HEATER, hose, hazardous loc. 1 1 1 1 1 1 1 1 1 1 1 1
273095 HEATER, hose, non-hazardous loc. 1 1 1 1 1 1 1 1 1
102 248208 HOSE, cpld, 4 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
103 17N598 HARNESS, SW3 to fluid A 1 1 1 1 1 1 1 1 1 1 1 1
104 17N599 HARNESS, SW4 to fluid B 1 1 1 1 1 1 1 1 1 1 1 1
105* 113796 SCREW, flanged, hex hd 8 8 8 8 8 8 8 8 8 8 8 8
106* 115942 NUT, hex, flange head 2 2 2 2 2 2 2 2 2 2 2 2
107 17P594 FITTING, assy, hose coupler, split 1 1 1 1 1 1 1 1 1 1 1 1
108 17S051 FITTING, assy, hose nipple, split 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1
manifold
110 113974 SCREW, thrd forming (10-24) 1 1 1 1 1 1 1 1 1 1 1 1
3A0420ZAC
Parts
PressureTrak Kit 17G808

,

WLD

$-
-
%-
Ref. Part Description Qty. Ref. Part Description Qty.

1 24Y281 MODULE, hazardous location 1 7 NXT403 SOLENOID, locking, DC 1
pressure monitor 8 ----- SCREW, flanged, hex hd 1
2 24Y932 HOUSING, PressureTrak, 1 9 ----- NUT, hex, flange head 1
machined 10 ----- CLAMP, cable 1
3 17G839 COVER, PressureTrak, NXT3400 1 11 ----- PACKING, o-ring 2
17G840 COVER, PressureTrak, NXT6500 1 12 24V216 KIT, repair, fuse assembly 1
4 17G837 SENSOR, PressureTrak, assy 1 13 15F716 LABEL, warning 1
5 - - - - - SCREW, high-low, flat head 2 14 NXT405 KIT, membrane shield 1
#6 x .625
 Replacement Danger and Warning labels are
6 - - - - - SCREW, thd forming 2
available at no cost.
70 3A0420ZAC
Parts
Bare Proportioning Pump Package

123 Model 571100 shown 122
137 101
136
103
129 138 122

3
3
128
109 6 7 8
1 106
102 1
2 3 104
110 7
121 105
1
133
4
101 134 135 139
107
108 1
111 113 5
131 140
116
117
3 112 117 or 118
119
116
130
120 1 108
130 r_258914_3A0420A_3a
r_258914_3A0420A_2a
1 Torque together to 50-60 ft-lb (68-81 N•m).

2 Torque to 145-155 ft-lb (196-210 N•m).
3 Apply blue thread sealant.
4 Insert lanyard from locking pin onto pumps (17, 18) as shown.
5 Do not apply lubricant.
6 Torque to 70-80 ft-lb (95-108 N•m).
7 Apply lithium grease to mating tapered surfaces.
8 Nuts with nylon patch - add anti-seize lubricant.
Nuts without nylon patch - add blue thread sealant.
3A0420ZAC 71
Parts
Parts Common to All Pump Packages Ref Part Description Qty

116 123976 RING, snap, external 2
Ref Part Description Qty
122 262474 COVER, pump 2
101 262465 PLATE, motor 1
128 15J277 CONTROL, de-ice 1
105 262468 ROD, tie, 14.25 long, with shoulder 4
130 124078 CLAMP, spring, constant-tension 2
106 262469 ROD, tie, 14.25 long, 1.25 dia 2
134 262475 BRACKET, ratio indicator 1
107 154636 WASHER, flat 3
135 16E882 STRAP, lowers 2
108 101712 NUT, lock, 5/8-11 9
136 --- SCREW, cap, button head, 10-32 8
109 16D451 NUT, yoke 1
137 124172 WASHER, retaining, nylon, 10-32 8
110 262470 BRACKET, ratio indicator 1
138 124665 NUT, captive, 10-32 4
111 262471 YOKE, pump assembly 1
139 15T468 LABEL, warning 2
112 15H392 ROD, adapter Xtreme 2
113 262472 SLEEVE, with bearing 2  Replacement Danger and Warning labels, tags, and cards are available at
no cost.
 Kit NXT112 (de-ice knob 5-pack) also available.
Parts Varying by Pump Package

Quantity (By Pump Package)
262803
281100
281200
281300
281400
282100
282150
282200
282250
282300
282330
282400
284101
284102
284103
284201
284202
284203
284251
284252
284253
284301
284302
284303
284401
284402
284403
571100
571150
571200
571250
571300
571400
Ref Part Description
102 262466 ROD, tie, 4.00 long 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
16M882 ROD, tie, 5.00 long 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
103 262818 MOTOR, hydraulic 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
N34DN0 MOTOR, 3400, de-icing 1 1 1 1 1
N65DN0 MOTOR, 6500,de-icing 1 1 1 1 1 1 1 1 1 1 1 1 1
104 262467 ROD, adapter 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
16M654 ADAPTER, motor 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
117 L085C0 PUMP LOWER, 85cc 1
L090C0 PUMP LOWER, 90cc 2 1 2 1 2
L115C0 PUMP LOWER, 115cc 1 1 1 1
L14AC0 PUMP LOWER, 145cc 1 1 1 2 1 2 1 1 1 1 1 1 1
L18AC0 PUMP LOWER, 180cc 1 1 1 1 1
L22AC0 PUMP LOWER, 220cc 1 1 2 1 1
L29AC0 PUMP LOWER, 290cc 1 1 1 1
118 L036C0 PUMP LOWER, 36cc 1 1 1
L048C0 PUMP LOWER, 48cc 1 1 1
L054C0 PUMP LOWER, 54cc 1 1 1 1
L058C0 PUMP LOWER, 58cc 1 1 1 1 1 1 1
L072C0 PUMP LOWER, 72cc 1 1 1 1
L097C0 PUMP LOWER, 97cc 1 1
119† 244819 COUPLING, for 1 1 1 2 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1
145-290cc pump lower
247167 COUPLING, for 1 2 2 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1
36-115cc pump lower
121 262473 COVER, motor rod 1 1 1 1 1 1 1 1 1 1 1 1 1
262704 COVER, motor rod 1 1 1 1 1
262734 COVER, motor rod 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
123 --- LABEL, identification 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
129 16D029 LABEL, XP70 1 1 1 1 1 1
16M178 LABEL, XP50 1 1 1 1 1 1 1
16M179 LABEL, XP35 1 1 1 1 1
131 15H108 LABEL, pinch point 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1
133 114225 TRIM, edge protection 1.3 1.3 1.3 1.3 1.3 2.1 2.1 2.1 2.1 2.1 2.1 2.1 2.1 2.1 2.1 2.1 2.1 1.3 2.1 2.1 2.1 2.1 2.1 1.3 2.1 2.1 1.3 2.1 2.1 2.1 2.1 2.1 2.1
140 238909 WIRE, grounding 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
244524 WIRE, grounding 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
141 16N396 LABEL, XP-h 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
142  16N375 LABEL, warning, multi- 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
lingual
198 206995 FLUID, tsl, 1 qt. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
199 16F615 TOOL, wrench, Xtreme 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
 Replacement Danger and Warning labels, tags, and cards are available at † Included with new pump assemblies (117, 118).
no cost.
 Not shown.
 Includes rupture disc 258962.
72 3A0420ZAC
Parts
Air Controls, 258983
201
206
203
209
2 214
206
207
Air Flow
216
214
215
208
211
213
204
Air Flow 202

211 205
209
210 TI17433a
1. Apply anaerobic pipe sealant to all non-swiveling pipe threads. r_571100_3A0420A_1a-1
2 Connect hose (214) to fitting (206) and air distribution manifold (213).
Qty Qty
Ref. No. Part No. Description . Ref. No. Part No. Description .
201 16F014 REGULATOR, air, T-handle 1 210a 106204 ELEMENT, filter; 3/4 npt 1
202 207675 MANIFOLD, air 1 211 157785 FITTING, union; 3/4 male x 2
203 113218 VALVE, ball 1 female
204 100509 PLUG; 1/4 npt 1 213 15E145 MANIFOLD, air distribution 1
205 100403 PLUG; 1/8 npt 1 214 16E004 HOSE, coupled, air; 26 in. 1
206 160327 FITTING, union, 90°; 3/4 male x 2 (660 mm)
female 215 157350 NIPPLE; 3/8 x 1/4 npt 3
207 101689 GAUGE, pressure, air 1 216 115781 CAP PLUG; 1/4 npt 3
208 155699 FITTING, elbow, street; 3/8 npt 3
209 119992 FITTING, pipe, nipple, 3/4 x 2  Not shown.
3/4 npt
210 117628 FITLTER, air, auto drain; 3/4 npt 1
3A0420ZAC 73
Parts
Fluid Circulation Manifold with Over Pressure Relief Valve

Assembly 262784 (XP35); 262783 (XP50); 262806 (XP70)
312
313 309
308
311 308
318 309
320 5
6 3 304
308 303
310
2 3 4 302 313
305
320 5
317 318
301
311
317
305
307 304 3 6
302 2 3 4
316
r_258988_3a0420a_1c
1. Apply anaerobic pipe sealant to all non-swiveling pipe
threads. 4 Further tighten either valve (302) as required to line
up handle straight across.
2 Torque to 28-32 ft-lb (38-43 N•m).
5 Apply grease to spring ends.
3 Apply blue anaerobic adhesive to threads.
6 Torque to 70-90 in-lb (7.9-9 N•m).
Ref Part Description Qty Ref Part Description Qty

301 16D693 BLOCK, manifold, recirculation 1 316 156684 FITTING, nipple, 1/2 npt x 1/2 npt 2
302† 262520 VALVE, over pressure relief, silver, 2 317 121399 O-RING, solvent resistant 2
XP70 318 124676 RING, snap, external 2
 262809 VALVE, over pressure relief, gold, XP50 2 320 150829 SPRING, compression 2
 262808 VALVE, over pressure relief, purple, 2 351 159239 FITTING, nipple, pipe, reducing 2
XP35 352 156173 UNION, swivel 2
303 156684 UNION; 1/2 in. male x female 2
304 112309 NUT, hex, jam 2  Not shown. Shipped loose.
305 198241 PLUG, port, pressure; 11/16-24 2  For XP35 systems only.
307† 114434 GAUGE, pressure, fluid, sst; 10k psi 2
 113654 GAUGE, pressure, fluid, sst; 5k psi 2  For XP50 systems only.
308 100840 FITTING, elbow, street; 1/4 npt 4
309 156971 FITTING, nipple; 1/4 npt x npsm 2 † For XP70 systems only.
310 557349 PLUG, dry seal 1/8 npt 2 NOTE: Loose fittings are supplied with replacement manifold
311 16E334 HANDLE, manifold 2 to also fit Series A XP Proportioners with 3/8 in. mix manifold
312 16E332 ROD, connecting, handle 1 ball valves.
313 124859 SCREW, button head 2
74 3A0420ZAC
Parts
Heated Hose Recirculation Pump

273093

D
WLE
1 Apply thread sealant to all non-swiveling pipe threads. 6 Orient fittings approximately 15 degrees away from pump.
2 Orient fittings as shown. 8 Install ground wire between screw and washer.
The nut is held in the slot of the pump.
4 Install two loose plugs and muffler provided with pump
in the ports indicated.
Mounted Heated Hose Parts List

301 108126 FITTING, tee, street 1 309 24T761 PUMP, acetal, w/pvdf check, 1
302 126897 FITTING, elbow, 1/2 tube x 1/4 2 Husky
NPTM 310 113161 SCREW, flange, hex hd 2
303 126898 FITTING, elbow, 1/2 tube x 1/2 1 311 17N910 TUBE, 35 in. x .5 OD, nylon 2
NPTM 312 17N911 TUBE, blue, .5 OD, nylon 1
304 126899 FITTING, 1/2 tube x 1/2 NPTM 1 (48 in. long)
305 16D939 FITTING, nipple, reducing 1 314 126900 FITTING, 1/2 tube x 3/8 NPTM 1
306 16R871 BOTTLE, overflow, 1/2 NPT 1 315 17D307 FITTING, nipple, quick coupling 1
307 17P088 BRACKET, XP-HF, re-circ, painted 1 318 17N795 WIRE, ground 1
308 206264 VALVE, needle 1
3A0420ZAC 75
Parts
Hose Heater (bracket mounted)

273095 (Non-Hazardous Locations)
273094 (Hazardous Locations)
D

E
F

WLE

3 Orient fittings as shown.

4 Tighten cord grip .75 in. back
5(' from cord cover end.
LQFP
5 Orient the port facing down.

410
BLACK BLACK
GREEN
WHITE BLACK
410
WLD
76 3A0420ZAC
Parts
Mounted Heated Hose Parts List
Ref. Part Description Qty. (273095) Qty. (273094)

401 245869 HEATER, paint, non-hazardous locations 1
245863 HEATER, paint, hazardous locations 1
402 24M221 BRACKET, heater, heated hose, paint 1 1
403 126898 FITTING, elbow, 1/2 tube x 1/2 NPTM 1 1
404 126896 FITTING, elbow, 1/2 tube x 1/2 NPTF 1 1
405 17P759 TUBE, 48 in. x .5 OD, nylon 1 1
406 126900 FITTING, 1/2 tube x 3/8 NPTM 1 1
407 17D306 FITTING, coupler, quick coupling 1 1
408 17N600 HARNESS, sw5 to hose heat 1
409 116171 BUSHING, strain relief 1
410 122032 NUT, wire 2
411 166590 FITTING, elbow, street 1
413 123443 SCREW, cap, flng hd 4 4
414 24M223 BRACKET, base, heated hose, painted 1 1
415 113981 NUT, lock, high tensile 4 4
3A0420ZAC 77
Parts
Enclosure Junction Box

Kit 273096*

[ WLE

1 Torque to 20-23 in-lb (2.2-2.6 N•m).

2 Torque to 55-60 in-lb (6.2-6.8 N•m).
3 Torque to 13-15 in-lb (1.5-1.8 N•m).

4 Torque to 25-28 in-lb (2.8-3.2 N•m).
5 Torque to 18-20 in-lb (2.0-2.3 N•m).

6 Torque to 10-12 in-lb (1.1-1.3 N•m).
8 Assemble with washer under ground
wire.
 Replacement Danger and Warning

labels, tags, and cards are available
at no cost.

WLD

78 3A0420ZAC
Parts
Enclosure Junction Box (continued)

Module 17N687
;I
;H
;J
CB01 CB02 CB03 CB04 CB05 CB06
WLD
D D F F E G

+233(5 +233(5 )/8,' )/8,' +26( 35(6685(
+($7(5 +($7(5 +($7(5 +($7(5 +($7(5 021,725
$ % $ %
Module 17N688
E F
G
WLD
D
3A0420ZAC 79
Parts
Enclosure Junction Box Parts List

82* 17P846 BRACKET, painted (not shown) 1 510 120859 NUT, strain relief, M40 thread 1
105* 113796 SCREW, 1/4-20 x .75 L 8 511 15U544 PLUG, hole, 1 1/8 in. 3
(not shown) 512 117666 TERMINAL, ground 1
106* 115942 NUT, flg hd, 1/4-20 (not shown) 2 513 115942 NUT, hex, flange head 1
501 - - - - - ENCLOSURE, XP, electrical 1 514 109466 NUT, lock, hex 3
502 123967 KNOB, operator disconnect 1 515 112948 SCREW, mach 1
503 123968 SWITCH, disconnect, ph exp 100 1 516 122313 BAR, ground, kit 1
amp 517 113783 SCREW, machine, pn hd 1
504 123969 SWITCH, disconnect, 100a (E-30) 1 518 113505 NUT, keps, hex hd 4
505 15U423 SWITCH, 2P, 25A 5 521 196548 LABEL, warning, shock 1
506 17N687 MODULE, din rail assy, circuit brk 1 524 17N590 HARNESS, term block to circuit 1
506a 17A311 CIRCUIT BREAKER, 2P, 10A, 2 bkr
UL489 525 17N592 HARNESS, circuit brkr to sw1, sw2 1
506b 17N315 CIRCUIT BREAKER, 2P, 25A, 1 526 17N593 HARNESS, circuit brkr sw3, sw4, 1
UL489 sw5
506c 17N316 CIRCUIT, BREAKER, 2P, 30A, 2 527 17N720 HARNESS, disconnect to term 1
UL489 block
506d 17C190 CIRCUIT BREAKER, 2P, 1A, 1 528 17N595 WIRE, ground, door to enclosure 1
UL489 529 17N594 WIRE, ground, gnd1 to gnd2 1
506e 17N690 BAR, power bus, 2P, 6 pin 2 530 17N601 HARNESS, circuit brkr-press 1
506f 17N691 CONNECTOR, terminal, buss bar 4 montr
506g 120838 BLOCK, clamp ends 2 531 114421 BUSHING, strain relief 1
507 17N688 MODULE, din rail assy, term blks 1 535 555629 WASHER, #10 lock external 2
507a 120570 MODULE, din rail assembly, 5 536 558685 WASHER, 1/4 external tooth lock 1
terminal blocks 537 15F674 LABEL, safety 1
507b 120490 COVER, end 1
507c 126811 BLOCK, clamp ends 2 *Kit includes these loose parts.
507d 120573 BRIDGE, plug in, jumper 2 Replacement Danger and Warning labels, tags,
508 116171 BUSHING, strain relief 2 and cards are available at no cost.
509 120858 BUSHING, strain relief, M40 1
thread
80 3A0420ZAC
Parts
Heater Wiring Diagram
SW5
1 3
Hose
Heater
2 4
SW4 SW3
1 3 1 3
Fluid Fluid
Heater B Heater A
2 4 2 4
SW2 SW1
1 3 1 3
Hopper Hopper
Heater B Heater A
2 4 2 4
WLD
Black Black
Black White
Green
Green White White
White White
HOSE HEATER
HOPPER HEATER A
Black Black
Black White
Green
Green Black Black
White White
White White
Green FLUID HEATER B

HOPPER HEATER B
White White
ACCESSORIES
FLUID HEATER A
3A0420ZAC 81
Parts
Heater Block Remote Manifold Kit

Kit 24Z934

[
WLD
[

[ [
1 Apply thread sealant to all non-swiveling 2 Supplied loose, not installed.

pipe threads.
Ref. Part Description Qty.

601 24F834 CARRIAGE, weldment, remote manifold 1
602 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, .375 (9.5 mm) ID (1.5 ft) 1
612* 054961 TUBE, blue, nylon, .375 (9.5 mm) ID (1.5 ft) 1
* Supplied loose, not installed.

 Replacement Danger and Warning labels, tags, and cards are available
at no cost.
82 3A0420ZAC
Recommended Spare Parts
Recommended Spare Parts

Keep these spare parts on hand to reduce downtime.
Pump Repair Kits 15K692, Seal Mix Manifold Check Valve

See Models (page 11) to see what pumps are used on Cartridge
your system. See lower manual for repair kits. NOTE: 15K692 must be replaced when cleaning the
check valves.
Pump Filter O-rings (packs of 10)
262483, Top o-ring 1/2 in. Mix Manifold Inlet Ball Valves
244895, Middle o-ring 24M601, Ball valve repair kit
262484, Bottom o-ring 262740, Spare valve (no handle)
262739, Spare valve (single handle)
Recirculation/Overpressure valve
(see page 56) 248927, Spare Mix Elements (pack of 25)
XP35: 262808, purple 1/2 in. OD x 12 element, acetal plastic
(also for use with XP-h 284x01 assemblies)
XP50: 262809, gold 248837, XTR Spray Gun Repair Kit
(also for use with XP-h 284x02 assemblies)
XP70: 262520, silver XHD010, Seat/Seal Kit for XHD™ RAC® Tips
(also for use with XP-h 284x03 assemblies) (5 pack)
XHDxxx, spray tips

See spray gun manual for tips.
3A0420ZAC 83

Acceptable For Use in Explosive 20 Gallon Hopper Kit, 255963
Atmospheres Floor Stand for 20 Gal. Hopper, 262824
N3400 PressureTrak Kit 17G807 1-1/2 in. ID Hose Flex Feed Kit, 262820
N6500 PressureTrak Kit 17G808
XP Wall Mount Bracket, 262812
Monitors pressures to provide ratio assurance on XP plural
component sprayers in hazardous and Works with air or hydraulic XP systems.
non-hazardous locations.
Leg Stand, 24M281
Blue 7 Gallon Hopper Kit, 24F376 Includes wall bracket 262812.
Green 7 Gallon Hopper Kit, 24F377
Mount to the sides of the XP system. See manual 406860 for 1/2 in. Ball Valve Upgrade Kit for Mix Manifold,
more information. 24M593
Solvent Pump Kit, 262393 Quickset Mix Manifold, 24M398

For supplying solvent to the mix manifold. See manual 310863 Mix manifold with independent A and B flushing for use with
for more information. quick hardening materials. See mix manifold manual 3A0590
for more information.
Desiccant Dryer Kit, 262454
For use with polyurethane isocyanates in 7 gallon hoppers. Remote Mix Manifold with Heater Block, 24Z934
See manual 406739 for more information. A mounting carriage with a heater block to circulate
water-jacketed hose heat to maintain heat on the mix
Desiccant Dryer Filter 2 Pack, 24K984
manifold.
Heater Adapter Kit, 262450

Remote Mix Manifold Carriage, 262522
Hose and fittings for connecting Viscon HP heaters to XP
A protective guard to mount mix manifold remote. See mix
system. See manual 406861 for parts. Purchase heaters
manifold manual 3A0590 for more information.
separately, see heater manual for part numbers.
Mix Manifold Restrictor Wrench, 126786
Twistork® Agitator Kit, 256274
For mixing viscous materials held within a 55 gallon drum. Gun Splitter with Carriage, 262826
See manual 312769 for more information. One splitter valve to use one, two, or three spray guns with the
system. Provides independent flush for two guns. Optional 3rd
5:1 Feed Pump Kit, 256276 gun port does not have independent flush. See manual
For supplying viscous materials from a drum to XP system. 3A2573 for more information.
See manual 312769 for more information.
DataTrak™ Conversion Kit, NXT606
5:1 Drum Feed Kit, 256255
Intrinsically safe battery operated NXT air motor accessory for
One 5:1 pump feed kit and one Twistork agitator kit for mixing material tracking system diagnostics and runaway control. See
and supplying viscous materials from a 55 gallon drum to XP manual 311486 for more information.
system. See manual 312769 for more information.

For supplying highly viscous material from a 55 gallon drum
to XP system. See manual 312769 for more information.
84 3A0420ZAC
Not Approved For Explosive Wall Powered Pressure Monitor Kit, 262940
Air Powered Pressure Monitor Kit, 262942
Atmospheres
Automatically monitors difference between A and B
These kits do not carry the EX mark. pressures when at spray pressure and shuts down the
system if there is a problem.
2:1 Feed Pump Kit, 256275
For supplying viscous materials from a drum to XP sys- GH™ Power Pack, 24X011
tem. See manual 312769 for more information.
Hydraulic power supply for XP-h systems. See manual
334914 for more information
One T2 pump feed kit and one Twistork agitator kit for
mixing and supplying viscous materials from a 55 gallon
drum to XP system. See manual 312769 for more infor-
mation.
3A0420ZAC 85
Dimensions
Dimensions
Top View
Bare System Full System
32 in. 35 in.
(813 mm) (889 mm)
52 in.
(1321 mm)
r_571100_3a0420_100a
Side View
XP System XP-h System
63 in.
(1600 mm)
62 in.
(1574 mm)
WLD
WLD
86 3A0420ZAC
Dimensions
Floor Mounting Dimensions, Top View
32 in.
(812.8 mm)
22 in.
(558.8 mm) 16.90 in.
(429.26 mm)
15.25 in.
6.75 in.
(387.35 mm)
(171.45 mm)
40 in.
(1016 mm)
3A0420ZAC 87
Dimensions
Bare Proportioner Mounting Hole Dimensions

The dimensions below is the minimum opening size for mounting a bare proportioner.
10.125 in.
(257.175 mm)
3/8-16 (4x) 5.06 in.

(128.52 mm)
120° (4x)
10.375 in.
(263.525 mm) 2.25 in.
150° (4x) (57.15 mm)
9.25 in.
4.05 in. (234.95 mm)
(102.87 mm) 0.25 in.
(6.35 mm)
3.75 in.
(95.25 mm)
7.5 in.
(190.5 mm)
14.35 in.
(364.49 mm)
88 3A0420ZAC
Dimensions
Wall Mount Bracket 262812 Dimensions
LQ
PP
LQ
PP
ti19046c
PP
PP
LQ
LQ
LQ
PP
3A0420ZAC 89
Dimensions
Floor Stand 24M281 Dimensions
21.2 in. 17.8 in.

(538 mm) (451 mm)
32.7 in.
(829 mm)
30.3 in.
(770 mm) ti19047a
Hydraulic Unit Dimensions

Shown installed on floor stand
53 in.
(1346 mm)
ti19048a
30.3 in. 17.8 in.

(770 mm) (451 mm)
90 3A0420ZAC
Technical Specifications
XP Proportioners
U.S. Metric
Maximum Fluid Working Pressure See Bare Proportioning Pump Packages (page 20).
Maximum Air/Hydraulic Oil Working Pressure See Bare Proportioning Pump Packages (page 20).
Combined Fluid Output (cc/cycle) See Bare Proportioning Pump Packages (page 20).
Pressure Ratio See Bare Proportioning Pump Packages (page 20).
Fluid Flow at 40 cpm See Bare Proportioning Pump Packages (page 20).
Hydraulic Fluid Consumption (XP-h models only) 0.2 gallons per cycle 0.76 liters per cycle
Air inlet size 3/4 npsm(f)
Maximum air pressure supply to the system 175 psi 12 bar, 1 MPa
Fluid pump inlets without hoppers 1-1/4 in. npsm(m)
Fluid gauge manifold outlets 1/2 in. npt(f)
Fluid mix manifold inlets 1/2 in. npt(f) ball valves
Mix manifold material outlet 1/2 in. npt(f)
Maximum feed pressure from remote source 250 psi 17 bar, 1.7 MPa
Sound pressure 86 dBA at 100 psi (7 bar, 0.7 MPa)
Sound power 98 dBA at 100 psi (7 bar, 0.7 MPa)
Maximum Storage Time 5 years (To maintain original performance, replace soft seals after 5 years
of inactivity.)
Power Efficiency Factor (XP70) 75 cu. ft compressed air/1 gallon 2.12 cubic meters compressed air/1 liter
sprayed material at 100 psi sprayed material at 7 bar (0.7 MPa)
Air consumption per 1 gallon (3.78 l) of flow
XP70 75 scfm at 100 psi/gpm 2.12 m3/min at 7 bar, 0.7 MPa
XP50 60 scfm at 100 psi/gpm 1/min at 7 bar, 0.7 MPa
XP35 50 scfm at 100 psi/gpm 1.42 cubic meters/min at 7 bar, 0.7 MPa
Electrical Specifications:
Configurable Voltage / Phase / Hz See Connect Power on page 29
Full Load Amps See Power Cord Requirements on page 29
Filtration:
Air inlet filtration 40-micron filter/separator included
XP pump outlets 30 mesh
XTR Spray Gun 60 mesh
Fluid Viscosity Range:
Gravity feed with 7 gallon (26 liter) hoppers 200 to 20,000 cps (pourable)
Pressure feed Any viscosity that will not require feed pressure more than 15% of outlet
pressure
Ambient Temperature Range:
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 manifolds Carbon steel with electroless nickel plating
Miscellaneous parts Plated carbon steel, stainless steels, carbide, acetal, UHMWPE, nylon,
PTFE solvent resistant plastics
Pump packings Carbon filled PTFE, proprietary UHMWPE
Flush pump suction tube Aluminum
Hoses Nylon core
3A0420ZAC 91
Weight:
XP35, XP50, or XP70 Pump only 286 lb 130 kg
XP-h Pump only 290 lb 132 kg
XP35, XP50, or XP70 Cart system with no 425 lb 193 kg
heaters, solvent flush pump, or hoppers
XP-h Cart system with no heaters, solvent flush 450 lb 204 kg
pump, or hoppers
Full XP35, XP50, or XP70 System with heaters, 575 lb 261 kg
solvent flush pump, and hoppers
Full XP-h System with heaters, solvent flush 600 lb 273 kg
pump, and hoppers
Complete unit with hoppers, solvent pump, A/B 665 lb 302 kg
non-hazardous location HP heaters, junction box
(57xxx5)
Complete unit with A/B/hose hazardous location 685 lb 311 kg
HP heaters, hose circulation pump, PressureTrak
(57xxx6)
Complete unit with A/B/hose non-hazardous loca- 725 lb 329 kg
tion HP heaters, junction box, hose circulation
pump, Pressure-Trak (57xxx7)
92 3A0420ZAC
Notes
Notes
3A0420ZAC 93
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.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 3A4381
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2016, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision ZAC, January 2018

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Operation, Repair, and Parts

XP™ and XP-h™

Important Safety Instructions

See Models section (starting on page 11) for model

FIRE AND EXPLOSION HAZARD

SPECIAL CONDITIONS FOR SAFE USE

SKIN INJECTION HAZARD

MOVING PARTS HAZARD

ELECTRIC SHOCK HAZARD

EQUIPMENT MISUSE HAZARD

PERSONAL PROTECTIVE EQUIPMENT

TOXIC FLUID OR FUMES HAZARD

Important Isocyanate (ISO) Information

Isocyanate Conditions Keep Components A and B

Spraying or dispensing fluids that contain isocyanates

Moisture Sensitivity of Changing Materials

NOTE: The amount of film formation and rate of crystal-

A and B Component Designations

Market Equipment Designations Machine Left Side Machine Right Side

Usage Over Pressure Protection

All systems noted by X (in Approval column) are Ex marked.

XP 35 with NXT Air Motor

HP Non-Hazardous Location Hose Heater

Hose Heat Circulation Pump

35 ft. (10.7m) Fluid Hose

XTR504 Spray Gun

psi (MPa, bar)

281101 X X X 3500 38:1 X X X

281201 X X X 3500 40:1 X X X

262804 X X X 3400 34:1 X X X

XP 35 with NXT Air Motor (continued)

HP Non-Hazardous Location Hose Heater

Hose Heat Circulation Pump

35 ft. (10.7m) Fluid Hose

XTR504 Spray Gun

psi (MPa, bar)

281301 X X X 3500 36:1 X X X

281401 X X X 3500 38:1 X X X

XP50 with NXT 6500 Air Motor

HP Non-Hazardous Location Hose Heater

HP Hazardous Location Hose Heater

PressureTrak (Hazardous Location)

Hose Heat Circulation Pump

35 ft. (10.7m) Fluid Hose

XTR504 Spray Gun

psi (MPa, bar)

282101 X X X 4500 45:1 X X X

282151 X X X 5000 55:1 X X X

282201 X X X 4800 48:1 X X X

282251 X X X 5000 52:1 X X X

XP50 with NXT 6500 Air Motor (continued)

HP Non-Hazardous Location Hose Heater

HP Hazardous Location Hose Heater

PressureTrak (Hazardous Location)

Hose Heat Circulation Pump

35 ft. (10.7m) Fluid Hose

XTR504 Spray Gun

psi (MPa, bar)

282301 X X X 4500 45:1 X X X

Bleed Type Motor Air Valve (CA) Air Filter (CC)