Graco Music Mixer 309909H User Manual

Repair - Parts  
309909H  
ENG  
Self-contained, single color, electronic plural component paint proportioner.  
For professional use only.  
Important Safety Instructions  
Read all warnings and instructions in this manual.  
Save these instructions.  
See page 3 for model information, including maxi-  
mum working pressure and approvals.  
TI4909a  
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ProMix Easy Models  
ProMix Easy Models  
WARNING  
Do not install equipment approved only for non-haz-  
ardous location in a hazardous area. Substitution of  
components may impair intrinsic safety and cause per-  
sonal injury. Read page 5.  
Approved for Hazardous Location  
Class I, Div 1, Group D (North America); Class I, Zones 1 and 2 (Europe)  
ProMix  
Easy  
Maximum Working  
Pressure  
Part No.  
Series  
Description  
psi (MPa, bar)  
Approvals  
234596  
A
250 (1.7, 17)  
Cart mount, UltraMix cst* Pumps, hose and gun  
Wall mount, UltraMix cst* Pump/G3000 Meter  
Wall mount, UltraMix sst** Pump/G3000 Meter  
Wall mount, UltraMix cst* Pumps  
234597  
234598  
234599  
234601  
234602  
A
A
A
A
A
250 (1.7, 17)  
250 (1.7, 17)  
250 (1.7, 17)  
250 (1.7, 17)  
2400 (16, 166)  
Conforms to  
FM std 3600 & 3610  
for use in  
Class I Div 1  
Group D T3  
Hazardous Locations  
Wall mount, UltraMix sst** Pumps  
Wall mount, HydraMix 500 cst* Pump/G3000 Meter  
234603  
234604  
234605  
234606  
234608  
234609  
234611  
234612  
234613  
234618  
234619  
A
A
A
A
A
A
A
A
A
A
A
2400 (16, 166)  
3400 (23, 234)  
3400 (23, 234)  
2400 (16, 166)  
2400 (16, 166)  
3400 (23, 234)  
3400 (23, 234)  
4700 (32, 324)  
4700 (32, 324)  
4000 (28, 280)  
4000 (28, 280)  
Wall mount, HydraMix 500 sst** Pump/G3000 Meter  
Wall mount, HydraMix 600 cst* Pump/G3000 Meter  
Wall mount, HydraMix 600 sst** Pump/G3000 Meter  
Wall mount, HydraMix 500 cst* Pumps  
ISSeP 04 ATEX 020X  
EEx ia p IIA T3  
Wall mount, HydraMix 500 sst** Pumps  
Wall mount, HydraMix 600 cst* Pumps  
0359  
Wall mount, HydraMix 600 sst** Pumps  
Wall mount, HydraMix 700 cst* Pumps  
Wall mount, HydraMix 700 sst** Pumps  
Wall mount, G3000 Meter, cst* mix manifold  
Wall mount, G3000 Meter, sst** mix manifold  
Approved for Non-hazardous Location  
CAN/CSA  
22.2 No. 157-92  
& No. 1010.1-92  
234600  
234825  
234607  
234826  
234610  
234827  
A
A
A
A
A
A
250 (1.7, 17)  
250 (1.7, 17)  
Wall mount, UltraMix cst* Pumps  
Wall mount, UltraMix sst** Pumps  
Wall mount, HydraMix 500 cst* Pumps  
Wall mount, HydraMix 500 sst** Pumps  
Wall mount, HydraMix 600 cst* Pumps  
Wall mount, HydraMix 600 sst** Pumps  
9902471  
Conforms to  
UL61010A-1  
Certified to  
2400 (16, 166)  
2400 (16, 166)  
3400 (23, 234)  
3400 (23, 234)  
CAN/CSA  
22.2 No. 1010.1-92  
* cst=carbon steel.  
** sst=stainless steel.  
309909H  
3
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Related Manuals  
Related Manuals  
Component Manuals in English  
This manual available in the following languages:  
Manual  
309908  
309909  
310654  
310655  
310662  
Description  
Manual  
309909  
310680  
310682  
310684  
310686  
310688  
310690  
310769  
310771  
310773  
Language  
English  
French  
ProMix Easy Operation  
ProMix Easy Repair-Parts  
Fluid Mix Manifold  
Dispense Valve  
Spanish  
German  
Italian  
UltraMix and HydraMix Displacement  
Pumps  
Chinese  
Japanese  
Dutch  
310671  
310672  
310673  
310674  
310675  
310676  
310677  
310678  
309192  
309623  
308778  
308034  
UltraMix Pumps  
HydraMix Pumps  
Circulation Kits  
Finnish  
Swedish  
Stand and Caster Kits  
AC Power Supply  
Remote Manifold Kit  
Heater Installation Kit  
TSL Pump Kits  
ISO Supply Kit  
Data Download Kits  
G3000 Flowmeter  
Turbine Alternator Repair Kit  
4
309909H  
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Warnings  
Warnings  
The following general warnings are related to the safe setup, use, grounding, maintenance, and repair of this equip-  
ment. Additional more specific warnings may be found throughout the text of this manual where applicable.  
WARNING  
FIRE AND EXPLOSION HAZARD  
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent  
fire and explosion:  
Use equipment only in well ventilated area.  
Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic  
drop cloths (potential static arc).  
Keep work area free of debris, including solvent, rags and gasoline.  
Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.  
Ground equipment and conductive objects in work area. See Setup instructions in ProMix Easy  
Operation manual 309908.  
Use only grounded hoses.  
Hold gun firmly to side of grounded pail when triggering into pail.  
If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment  
until you identify and correct the problem.  
Keep a fire extinguisher in the work area.  
SKIN INJECTION HAZARD  
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like  
just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.  
Do not 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.  
Do not spray without tip guard and trigger guard installed.  
Engage trigger lock when not spraying.  
Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,  
checking, or servicing equipment.  
MOVING PARTS HAZARD  
Moving parts can pinch 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 in this manual. Disconnect power or air supply.  
309909H  
5
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Warnings  
WARNING  
EQUIPMENT MISUSE HAZARD  
Misuse can cause death or serious injury.  
Do not exceed the maximum working pressure or temperature rating of the lowest rated system  
component. See Technical Data in all equipment manuals.  
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all  
equipment manuals. Read fluid and solvent manufacturer’s warnings.  
Check equipment daily. Repair or replace worn or damaged parts immediately.  
Do not alter or modify equipment.  
For professional use only.  
Use equipment only for its intended purpose. Call your Graco distributor for information.  
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.  
Do not kind or overbend hoses or use hoses to pull equipment.  
Comply with all applicable safety regulations.  
TOXIC FLUID OR FUMES HAZARD  
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or  
swallowed.  
Read MSDS’s to know the specific hazards of the fluids you are using.  
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.  
PERSONAL PROTECTIVE EQUIPMENT  
You must wear appropriate protective equipment when operating, servicing, or when in the operating  
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic  
fumes, burns, and hearing loss. This equipment includes but is not limited to:  
Protective eyewear  
Clothing and respirator as recommended by the fluid and solvent manufacturer  
Gloves  
Hearing protection  
6
309909H  
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Pressure Relief Procedure  
Pressure Relief Procedure  
3. Disengage trigger lock.  
WARNING  
Relieve pressure from fluid manifold to gun whenever  
you stop spraying and before servicing gun or remov-  
ing spray tip.  
4. Hold a metal part of the gun firmly to a grounded  
In addition, relieve pressure from pump to fluid mani-  
fold at end of day and before cleaning, checking, or  
servicing pump, manifold, or fluid line accessories or  
transporting equipment.  
metal pail. Trigger gun to relieve pressure.  
Read warnings, page 5.  
Fluid Manifold to Gun  
1. Engage trigger lock.  
5. Engage trigger lock.  
2. Press  
.
309909H  
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Pressure Relief Procedure  
5. Open sampling valve A slowly to bleed off pressure.  
Indicator A will stay on for 5 sec after Pump A  
reaches Park position, then go off.  
Pump to Fluid Manifold  
A
B
1. Close shutoff valves G and G .  
A
Pump air supply pressure must be sufficient to  
cause pumps to stroke to bottom-most position  
when function knob to is set to pressure relief/park  
2. Place waste container under sampling valves H  
B
and H .  
.
B
B
H
G
A
H
A
G
TI4699a  
3. Turn function knob to pressure relief/park  
.
6. Indicator B comes on and Pump B pressurizes.  
7. Open sampling valve B slowly to bleed off pressure.  
Indicator B will stay on for 5 sec after Pump B  
reaches Park position, then go off.  
4. Press  
surizes.  
. Indicator A comes on, and Pump A pres-  
If both pumps are not parked after 1 min, Alarm  
26 will sound.  
8. Close sampling valves A and B before restarting  
system.  
8
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Maintenance  
Maintenance  
Preventive Maintenance  
Schedule  
Establish a preventive maintenance schedule, based on  
the pump’s repair history.  
Pump Test/Meter Calibration  
See ProMix Easy Operation manual. If pumps/meters  
fail test, see Troubleshooting, page 10.  
Wet Cup  
Check pump and dispense valve wet-cups daily. Keep  
filled with Graco Throat Seal Liquid (TSL), Part No.  
206995.  
Mix Manifold  
See mix manifold manual 310654.  
Dispense Valve  
See dispense valve manual 310655.  
Storage  
Before storing the pump, always flush it, see ProMix  
Easy Operation manual. Relieve the pressure, page 7.  
Pump  
Icing  
See applicable pump manual 310671, 310672, or  
310662.  
If you experience icing at the pump air manifold:  
Reduce pump input air pressure below 80 psi (0.56  
MPa, 5.6 bar), if required spray pressure allows.  
Turbine Alternator  
Replace bearings every 2000 hours. See page 19.  
Reduce moisture in compressed air supply, or use  
heated air.  
Air Filters  
If icing persists, see table below.  
Check daily. Drain and clean as necessary. See page  
15.  
Problem  
Solution  
Turn D port bleed screw 60° (1/6 turn) counter-  
Pump slows on both up  
and down stroke.  
clockwise, to bleed 1 cfm air to melt ice.  
Pump slows on down  
stroke.  
Turn D port bleed screw 60° (1/6 turn) counter-  
clockwise, to bleed 1 cfm air to melt ice. If icing  
continues, turn screw to 90° (1/4 turn) to increase  
air flow to 2 cfm. If necessary, increase air flow to  
3 cfm by turning screw to 270° (3/4 turn). Do not  
exceed 3 cfm (3/4 turn maximum).  
U
D
Pump slows on up stroke.  
Turn U port bleed screw 90° (1/4 turn) counter-  
clockwise, to bleed 1 cfm air to melt ice. If icing  
continues, turn screw to 120° (1/3 turn) to  
increase air flow to 2 cfm. If necessary, increase  
air flow to 3 cfm by turning screw to 180° (1/2  
turn). Do not exceed 3 cfm (1/2 turn maximum).  
TI5294a  
309909H  
9
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Troubleshooting  
Troubleshooting  
If an alarm code displays, see page 13.  
WARNING  
Read warnings, page 5-6.  
Problem  
Cause  
Solution  
Display not lit.  
Air valve not turned on.  
Turn on main air valve to system.  
No electric power.  
Air supply pressure too low.  
Increase pressure to 60 psi (0.42 MPa,  
4.2 bar) or greater.  
Air supply filters plugged.  
Clean filter bowls; replace filter elements.  
Page 15.  
Turbine air regulator set too low.  
Turbine alternator failure.  
Adjust to proper setting.  
Repair or replace turbine. Page 19.  
Power supply not connected to main  
board.  
Check power connections to main board.  
See Electrical Schematic, page 22.  
Main board not connected to display  
board.  
Check electrical connections between  
display and main board. See Electrical  
Display board failure.  
Replace display board. Page 18.  
Power not connected to unit (non-IS units Ensure that power cord is plugged in.  
only).  
Check that cord is connected properly;  
see ProMix Easy Operation manual.  
Pumps do not run.  
Air pressure to pumps too low.  
Solenoid valve stuck.  
Increase pressure to 50 psi (0.35 MPa,  
3.5 bar).  
Actuate solenoid manually, if it does not  
operate, replace solenoid. Page 20.  
Dispense valve(s) not opening.  
Air pressure to pumps too low  
Service or replace valve(s). See 310655.  
Pump test volume is not correct.  
Increase pressure to 50 psi (0.35 MPa,  
3.5 bar).  
Sensors not functioning properly.  
Check position of sensors. See ProMix  
Easy Operation manual, and applicable  
pump manual.  
Check board calibration and recalibrate if  
necessary. See ProMix Easy Operation  
manual.  
Replace sensors. See pump manual  
310671 or 310672.  
Pump cavitating excessively.  
Check for air in lines caused by loose fit-  
ting or use of agitator.  
Material too viscous. Use heater.  
10  
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Troubleshooting  
Problem  
Cause  
Solution  
Paint does not cure consistently.  
Ratio not set correctly.  
Check that correct ratio is set and set by  
volume. See ProMix Easy Operation  
manual.  
Material not mixing correctly.  
Pump not operating correctly.  
Test pump. Page 9.  
Make sure mixer is clean; flush as  
needed. See ProMix Easy Operation  
manual.  
Observe whether pumps are loading and  
checking correctly, if not, clean and repair  
pump. See displacement pump manual  
310662.  
Poor spray pattern.  
Fluid pressure too low.  
Spray tip dirty or worn.  
Increase pump pressure.  
Relieve pressure. Clean or replace tip.  
Follow gun manual instructions.  
Fluid A or B filters plugged.  
Clean filters.  
Mixer or hoses partially plugged or too  
restrictive.  
Inspect parts for cured material. Clean or  
replace, or use larger hoses and mixer.  
System runs erratically.  
Air filter(s) clogged. Replace elements.  
Air supply hoses undersized.  
Clean. Replace element(s). See page 15.  
Replace hoses with appropriate size.  
Use larger air compressor.  
Air compressor undersized.  
Air supply pressure tank undersized.  
Turbine air regulator set too high.  
Use larger pressure tank.  
Air supply relief valve opens.  
Lower setting to 23-25 psi (172-241 kPa,  
1.7-2.4 bar).  
Turbine alternator makes high-pitched  
whining noise.  
Turbine bearings worn. (Setting turbine  
air regulator too high, wears bearings.)  
Replace bearings. Page 19.  
Display shows 88888 or unit reboots  
unexpectedly.  
Turbine is not supplying enough power to Increase turbine regulator setting to  
board.  
23-25 psi (172-241 kPa, 1.7-2.4 bar).  
Check turbine and electrical control  
exhaust air for restrictions.  
Replace turbine bearings. Page 19.  
ProMix Easy does not start when start  
button is pressed.  
Faulty start switch or wire harness.  
Faulty stop switch or wiring harness.  
Check start switch and wiring harness  
continuity; switch is normally open circuit.  
See Electrical Schematic, page 22.  
Check stop switch and wiring harness  
continuity; stop switch is normally closed  
circuit. See Electrical Schematic, page  
Bad I/O port on display board.  
Bad I/O port on main board.  
Loose or worn packings.  
Replace board. Page 18.  
Replace board. Page 17.  
Dispense valves leaking.  
Tighten packing nut. If leak continues,  
replace packings. See 310655.  
309909H  
11  
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Troubleshooting  
Problem  
Cause  
Solution  
Flow rate too low.  
Inadequate air supply.  
Use larger CFM compressor.  
Increase pressure.  
Clean filters.  
Air pressure to pumps too low.  
Fluid A or B filters plugged.  
Spray tip too small.  
Relieve pressure. Install larger tip. Follow  
gun manual instructions.  
Mixer or hoses partially plugged or too  
restrictive.  
Inspect parts for cured material. Clean or  
replace, or use larger hoses and mixer.  
Insufficient dispense valve travel.  
Shutoff valves are not fully open.  
Increase travel. See 310655.  
Ensure that shutoff valves are fully open  
and sampling valves are closed.  
Turn knob to spray  
rial.  
if spraying mate-  
Knob is set to Run pump A  
or B  
Pump stops after 12 cycles.  
independently.  
Pump cycle rate slows and eventually  
stops.  
Icing at pump air manifold.  
See Icing, page 9.  
12  
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Alarms  
Alarms  
*
Indicates error where audible alarm sounds once briefly.  
** Indicates error where audible alarm sound pulses.  
Code  
Alarm  
Active  
Problem  
Cause  
Startup Errors  
01  
02  
03  
Sensor Error A*  
Always No signal from pump A  
sensor  
Loose cable, failed sensor or cable, failed magnet  
assembly  
Sensor Error B*  
Always No signal from pump B  
sensor  
Loose cable, failed sensor or cable, failed magnet  
assembly  
Communication Error*  
Always Loss of communication  
between main and dis-  
play boards  
Loose cable, failed board  
Operating Errors  
not used  
04  
05  
06  
07  
not used  
Pump Error A**  
Pump Error B**  
Spray  
Test  
Pump does not stall after Intake valve leak  
top change over  
Batch  
Pump cavitating exces-  
sively  
Air in lines caused by loose fitting or use of agitator  
Empty fluid supply  
08  
09  
Sensor Code Error  
Metering Error A**  
Always Sensor values reverted to Sensor value data corrupt; board needs replacement  
default  
and /or recalibration  
Spray  
A dose too great  
Dispense valve A leak  
Empty B fluid supply  
Clogged flow meter  
10  
Metering Error B**  
Spray  
B dose too great  
Dispense valve B leak  
Empty A fluid supply  
Clogged flow meter  
11  
12  
Sensor Reading Low A*  
Sensor Reading Low B*  
Spray  
Test  
Batch  
Pump stroke travels  
beyond sensor range at  
top change over  
Sensor or bracket loose  
Sensor magnet dirty  
13  
14  
Sensor Reading High A*  
Sensor Reading High B*  
Spray  
Test  
Batch  
Pump stroke travels  
beyond sensor range at  
bottom change over  
Sensor or bracket loose  
Sensor magnet dirty  
21  
Pot Life Error  
Spray  
first, then  
Always  
Pot life timer timed out  
Not enough material sprayed after last reset  
309909H  
13  
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Alarms  
Code  
Alarm  
Active  
Problem  
Cause  
Operating Errors  
(continued)  
22  
23  
24  
25  
High Ratio (units with  
meter[s] only)  
Spray  
Spray  
Spray  
Mix ratio higher than  
Target + Tolerance  
Flow rate too high  
Slow actuation of dispense valve A or B  
Clogged flow meter  
Low Ratio (units with  
meter[s] only)  
Mix ratio lower than  
Target - Tolerance  
Dose Timeout A (units  
with meter[s] only)  
Air flow switch indicates Air flow switch stuck open.  
more than 40 sec of air  
flow without dose com-  
pleting  
Atomizing air leak downstream of air flow switch.  
Dose Timeout B (units  
with meter[s] only)  
Clogged flow meter.  
Gun triggered without fluid (dusting parts)  
Sampling valves closed, or gun not triggered.  
26  
Park Timeout  
(pump-based units only)  
Park  
Pumps not at bottom of  
stroke  
Testing Error  
Piston packing/ball A*  
Piston packing/ball B*  
Inlet Ball A*  
15  
16  
17  
18  
19  
20  
Test  
Test  
Test  
Pump does not com-  
pletely stall in up stroke  
Piston packing or ball check failure  
Intake valve ball check failure  
Pump does not com-  
pletely stall in downstroke  
Inlet Ball B*  
Dispense Valve A*  
Dispense Valve B*  
Pump does not com-  
pletely stall in both up  
and down strokes  
Throat packing or dispense valve failure  
27  
28  
Pump Calibration  
Timeout A  
Run A Pump doesn’t run  
through calibration.  
Sampling valves closed.  
Pump Calibration  
Timeout B  
Run B  
14  
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Repair  
Repair  
Flush before repairing equipment, if possible. See Pro-  
Mix Easy Operation manual.  
Replacing Air Filter Element  
There are 2 air filters on the unit: the 5 micron air mani-  
fold filter (7) and 40 micron pump air filter (9). Check fil-  
ters daily and replace element as needed. Order  
15D909 5 micron filter and 15D890 40 micron filter.  
WARNING  
Read warnings, page 5.  
WARNING  
Follow Pressure Relief Procedure, page 7, if service  
time may exceed pot life time, before servicing fluid  
components, and before transporting equipment to a  
service area.  
Removing the bowl of a pressurized air filter could  
cause serious injury. Do not service air filter until air  
line is depressurized.  
1. Close main air shutoff valve on air supply line and  
on unit.  
2. Remove left side plate (21).  
3. Unlock filter bowl guard and remove.  
4. Unscrew filter bowl.  
5. Remove and replace element.  
6. Screw filter bowl on securely.  
7. Reassemble.  
309909H  
15  
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Repair  
Software Upgrades  
User Interface  
CAUTION  
Removal  
To avoid damaging circuit board, wear a grounding  
strap.  
1. Close main air shutoff valve on air supply line and  
on unit.  
1. Remove User Interface cover. See above.  
2. Remove side panels (21).  
2. Use a chip remover (D) to remove software chip (C).  
FIG. 2.  
3. Remove fasteners (45). Gently pull user interface  
(11) away from pneumatic control (10).  
10  
315  
21  
C
D
45  
FIG. 2  
3. Install new chip (beveled corner down).  
4. Reassemble.  
11  
TI4901a  
5. Recalibrate main circuit board. See ProMix Easy  
Operation Manual.  
FIG. 1  
4. To completely remove user interface (11), discon-  
nect ground wire (315), and wires (416 and 406)  
from main control board (301). See Electrical  
Schematic, page 22.  
16  
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Repair  
Replacing Main Circuit Board  
CAUTION  
To avoid damaging circuit board, wear a grounding  
strap.  
1. Remove User Interface cover. See page 16.  
2. Disconnect all wire connectors from board (301).  
FIG. 3.  
3. Remove four screws (302) and replace board (301).  
4. Reassemble. Refer to Electrical Schematic, page  
22.  
5. Recalibrate system. See ProMix Easy Operation  
Manual.  
NOTE: If the main control board is replaced on  
units that use a flow meter, the flow meter calibra-  
tion data must be set using a PC and a Data  
Download Kit (Graco P/N 248403 for hazardous  
locations or Graco P/N 248404 for non-hazardous  
locations).  
320  
301  
TI4561a  
FIG. 3  
309909H  
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Repair  
3. Remove two screws (411).  
Replacing Display Circuit Board  
4. Loosen setscrew (419) from knob (405) and remove  
knob assembly. Remove jam nut (N).  
CAUTION  
To avoid damaging circuit board, wear a grounding  
strap.  
5. Remove and replace display board (410).  
6. Reassemble. Refer to Electrical Schematic, page  
1. Remove User Interface cover. See page 16.  
22.  
2. Disconnect wires from display board (410). FIG. 4.  
404  
N
413 418  
410  
411  
407  
406  
405  
407  
403  
419  
416  
403  
406  
401  
416  
TI4755a  
TI4756a  
FIG. 4  
18  
309909H  
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Repair  
Lightly lubricate turbine o-ring before install-  
ing turbine in housing.  
Connect alternator red wire to + side and  
black wire to – side of main circuit board.  
Connect turbine to 3-pin connector on main  
circuit board.  
Pneumatic Control  
Alternator Repair  
Turbine Alternator Repair Kit 223688 is available to  
replace turbine bearings.  
1. Remove User Interface cover. See page 16.  
P
304  
305  
304  
304d  
306r  
301  
310  
FIG. 6  
310  
A
304a  
1
304d  
313  
TI4561a  
FIG. 5  
2. Disconnect power supply wires (P). FIG. 5.  
304e  
3. Disconnect two air lines (310) from alternator (304).  
FIG. 6.  
1
Torque to 20 in-lbs (2 N•m)  
4. Remove top nut (305) and loosen bottom nut. Slide  
alternator up and off bottom nut.  
FIG. 7  
5. Remove four screws (304d) to separate alternator  
housings. FIG. 7.  
6. Disconnect turbine (304e) from board (A). Follow  
instructions in turbine kit manual 308034 to remove  
and repair turbine.  
7. Replace gasket (304a) if damaged. Place between  
housings before securing with screws (304d).  
8. Reassemble. Refer to Electrical Schematic, page  
22.  
309909H  
19  
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Repair  
3. Disconnect supply and exhaust air lines (310). FIG.  
5, page 19.  
Replacing Solenoids  
Follow this procedure to replace a single solenoid.  
4. Disconnect solenoid wires 12 position Phoenix con-  
nector (306r) from main board.  
1. Remove User Interface cover. See page 16.  
2. Disconnect two solenoid wires (V) from main board.  
FIG. 8.  
5. Remove solenoid module (306) with regulator  
(306e). FIG. 8.  
3. Disconnect dispense valve pilot lines (A1, A2, B1,  
B2). FIG. 8.  
6. Unscrew and replace regulator (306e).  
7. Reassemble. Refer to Electrical Schematic, page  
4. Remove two screws (S).  
22.  
5. Remove and replace solenoid (306b).  
Make sure gaskets (306j, 306k) are in place when  
reinstalling solenoid module.  
From left to right, solenoid functions are as follows:  
Component A  
Component B  
8. Set regulator to 24 psi (160 kPa, 1.6 bar).  
Replacing Alarm  
6. Reassemble. Solenoid wires are polarized (red +,  
black –). Refer to Electrical Schematic, page 22.  
1. Remove User Interface cover. See page 16.  
2. Disconnect alarm wires from main board.  
Replacing Alternator Regulator  
1. Remove User Interface cover. See page 16.  
3. Unscrew alarm (313) and replace. FIG. 5, page 19.  
2. Remove two screws (309) from the back of the con-  
trol box.  
4. Reassemble. Refer to Electrical Schematic, page  
22.  
Dispense Valve  
Pilot Lines  
1
2
Set regulator pressure to 24 psi (160 kPa, 16 bar).  
310  
Safety relief valve (306t) is required on all IS units.  
A1 (off), clear tube  
A2 (on), black tube  
B1 (off), green tube  
B2 (on), red tube  
306e  
1
V
B1  
A
B
A1  
B2  
A2  
306t  
2
306k  
B2  
306j  
S
306b  
A2  
TI4699a  
TI4558a  
A1  
B1  
FIG. 8  
20  
309909H  
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Repair  
Dispense Valve/Mix Manifold Pump Assembly  
Assembly  
WARNING  
WARNING  
Read warnings, page 5.  
Read warnings, page 5.  
See the Parts drawing for your model.  
See the Parts drawing for your model.  
2. Remove side plates (21).  
2. Label all air and fluid lines, and disconnect from fit-  
tings on manifold assembly.  
3. Remove wire harnesses from sensor and solenoids.  
Refer to Electrical Schematic, page 22.  
3. Remove fasteners.  
4. Disconnect fluid inlet and outlet lines from pump  
lower. Disconnect air supply from pump.  
4. Remove mix manifold (2).  
5. Label all tubing and disconnect from fittings on  
pump assembly.  
5. To repair mix manifold, see manual 310654. To  
repair dispense valves, see manual 310655.  
6. Remove mounting hardware and slide pump out of  
frame.  
6. Reassemble.  
7. Repair as instructed in pump manuals 310671,  
310672, or 310662.  
8. Reassemble.  
309909H  
21  
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Electrical Schematic  
Electrical Schematic  
1
22  
309909H  
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248349 Main Control Board Schematic  
248349 Main Control Board Schematic  
Pin 1  
Pin 1  
248349 Main Control Board LEDs  
LED  
Description  
D2  
In normal operation D2 flashes on and off in 1  
second intervals. If D2 is off (not flashing),  
software is not booting; check for power to  
the board or a short circuit.  
J6  
F1  
J5  
D12 D6 D13 D5 D10  
D5  
D6  
On: Dispense valve B is on (open).  
Off: Dispense valve B is off (closed).  
U4  
J4  
Active only on units with recirculation option.  
On: Recirculation solenoid is on.  
Off: Recirculation solenoid is off.  
Pin 1  
D10  
D12  
D13  
On: Dispense valve A is on (open).  
Off: Dispense valve A is off (closed).  
D2  
J1  
On: Remote alarm output on.  
Off: Remote alarm output off.  
J2  
J8  
D13 is always off. Output powers the 246899  
Expansion Board, turning the board on and  
off.  
Pin 1  
Pin 1  
Pin 1  
TI11316a  
246899 Pump Solenoid Expansion Board Schematic  
246899 Pump Solenoid Expansion Board LEDs  
LED  
Description  
D1  
D2  
D3  
D4  
On: Pump B is on the downstroke.  
On: Pump B is on the upstroke.  
On: Pump A is on the downstroke.  
On: Pump A is on the upstroke.  
Pin 1  
D1  
D2  
D3  
D4  
P3  
P2  
P1  
S
G
P
1
P4  
Pin 1  
TI11229a  
309909H  
23  
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Parts  
Parts  
Part No. 234596 Series A, Pump-based, Cart-mounted Air Spray Unit  
10  
22  
39  
11  
85  
21, 28  
22  
51  
45  
20  
38  
79  
41  
22  
21  
103  
104  
71  
102  
71  
30  
100  
72  
101  
101 (Ref)  
73  
98  
81  
84  
101 (Ref)  
TI4769a  
24  
309909H  
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Parts  
Part No. 234596 Series A, Pump-based, Cart-mounted Air Spray Unit, continued  
46  
37  
1
65 (Ref)  
39  
16 17  
47  
74  
82  
76  
65  
67  
17  
75  
63  
16  
15  
9
15  
32  
33  
40  
47  
25  
49  
48  
3
5
15  
7
4
24  
8
45  
31  
6
32  
33  
12  
24 (Ref)  
23  
14  
45  
16  
17  
44  
78  
2
Pump Solenoid  
Cable Connections  
63  
78 (Ref)  
2
1
TI4770a  
1
2
Downstroke solenoid is on the outside.  
Upstroke solenoid is on the inside.  
TI11228a  
309909H  
25  
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Parts  
Part No. 234596 Series A, Pump-based, Cart-mounted Air Spray Unit, continued  
Ref.  
No.  
Ref.  
No.  
Part No.  
Description  
Qty.  
Part No.  
Description  
Qty.  
1
1
46  
47  
48  
49  
51  
56  
57  
58  
59  
60  
113319  
FITTING, air; 1/4 npt(m) x  
3/8 in. (10 mm) OD tube  
ELBOW; 1/4 npt(m) x  
3/8 in. (10 mm) OD tube  
FITTING, Y-adapter;  
1/4 in. (6 mm) OD tube  
ADAPTER; 3/8 in (10 mm) tube x  
1/4 in. (6 mm) tube  
1
2
3
4
5
6
15D771  
234593  
287230  
109544  
116756  
155665  
FRAME, wall mount  
1
1
1
1
MIX MANIFOLD; see 310654  
CONTROL, air; see page 53  
ELBOW, pipe; 3/8 npt (mbe)  
ELBOW, street, 45°; 3/8 npt (m x f)  
UNION, adapter; 3/8 npsm(f) x  
3/8 npt(m)  
2
2
115841  
114158  
115743  
116780  
598095  
054753  
054754  
054757  
590385  
1
2
1
1
7
8
117629  
114316  
FILTER, air; 5 micron  
ELBOW; 3/8 npt(m) x  
2
SCREW, hex hd flanged;  
3/8-16 x 1-3/4 in. (44 mm)  
TUBE; nylon; 5/32 in. (4 mm) OD;  
clear; see pages 44 and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
black; see pages 44 and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
red; see pages 44 and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
green; see pages 44 and 47  
TUBE; polyethylene; 3/8 in. (10 mm)  
OD; see pages 44 and 47  
NIPPLE; 1/4 npsm x 1/4 npt  
FITTING, bulkhead  
ELBOW, street; 1/4 npt (m x f)  
TUBE; nylon; 1/4 in. (6 mm) OD;  
see pages 44 and 47  
NUT, hex, flange hd; 3/8-16  
SCREW, cap; 3/8-16 x 3 in. (76 mm)  
WHEEL  
REGULATOR, air  
GAUGE, pressure, air  
NUT, regulator  
HOSE, fluid; 1/4 npsm (fbe); PTFE;  
1/4 in. (6 mm) ID; 18 in. (457 mm);  
see also pages 44 and 47  
BUSHING, strain relief  
RING, retaining  
ELBOW, street; 1/8 npt (m x f)  
BUSHING, wheel  
3/8 in. (10 mm) OD tube fitting  
FILTER, air; 40 micron  
PNEUMATIC CONTROL,  
intrinsically safe; see page 54  
USER INTERFACE; see page 52  
PUMP, UltraMix; see 310671  
BRACKET, support, fluid manifold  
ELBOW; 1/2 npt(m) x  
2 ft  
2 ft  
2 ft  
2 ft  
9 ft  
1
1
9
10  
15D795  
248270  
1
2
1
3
11  
12  
14  
15  
234620  
248570  
15D873  
C38211  
3/8 in. (10 mm) OD tube  
WASHER, lock; 1/4  
5
5
16  
17  
C19038  
112925  
SCREW, cap, button hd;  
1/4-20 x 3/8 in. (10 mm)  
SCREW, machine, phillips;  
8-32 x 7/16 in. (11 mm)  
PLATE, side  
3
1
1
4.2  
ft  
4
2
2
1
1
63  
65  
67  
70  
162453  
104641  
100840  
054123  
4
20  
103196  
2
20  
8
21  
22  
23  
15D767  
119291  
113802  
SCREW, self-tapping  
71  
72  
73  
74  
75  
76  
78  
112958  
116935  
198720  
116513  
108190  
116514  
206966  
SCREW, hex hd, flanged;  
3/8-16 x 5/8 in. (16 mm)  
HOSE, air; nitrile; 1/2 in. (13 mm)  
ID; 1/2 npt (mbe); 18 in. (457 mm);  
see also pages 44 and 47  
ELBOW, swivel; 1/2 npt(m) x  
1/2 npsm(f)  
CABLE, sensor; see Electrical  
HARNESS, connector; see Electri-  
LABEL, warning  
CART  
GROMMET  
COUPLING; 1/8 npt (fbe)  
CONNECTOR; 1/8 npt(m) x  
1/4 in. (6 mm) OD tube  
GROUND WIRE  
1
24  
220598  
1
2
1
2
2
25  
26  
27  
C19024  
15D607  
15D794  
2
2
1
2
1
2
1
1
79  
81  
82  
84  
85  
98  
100  
101  
195889  
113436  
160701  
15E106  
15D986  
154628  
239561  
233498  
1
1
2
2
2
28290331  
30  
31  
32  
33  
15D775  
101765  
100451  
115671  
PLATE, rear  
WASHER  
GUN, spray, HVLP; see 308741  
HOSE ASSEMBLY; 3/8 npsm (f)  
nylon fluid hose; 1/4 npsm(f) air  
hose; 25 ft (7.6 m)  
NIPPLE; 3/8 npt x 3/8 npsm  
ELBOW, swivel; 3/8 npt(m) x  
1/4 npsm(f)  
1
2
37  
38  
244524  
113279  
PLUG, tube fitting;  
1
1
102  
103  
162485  
155495  
5/32 in. (4 mm) OD tube  
NUT, keps, hex hd; 10-24  
SCREW, cap, button hd;  
10-32 x 3/8 in. (10 mm)  
CAP  
SCREW, machine; 1/4-20 x  
1-1/2 in. (38 mm)  
NUT, hex, flange hd; 1/4-20  
2
4
39  
40  
113505  
551787  
1
104  
214706  
REGULATOR, pressure, fluid;  
see 307212  
2
1
41  
44  
111218  
114104  
Replacement Danger and Warning labels, tags, and cards  
are available at no cost.  
7
45  
115942  
26  
309909H  
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Parts  
Pump and Meter-based, Wall-mounted Air Spray Units  
Part No. 234597 Series A, UltraMix carbon steel pump and G3000 Meter  
Part No. 234598 Series A, UltraMix stainless steel pump and G3000 Meter  
10  
39  
11  
21, 28  
22  
45  
22  
20  
38  
79  
TI4901b  
21  
309909H  
27  
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Parts  
Pump and Meter-based, Wall-mounted Air Spray Units, continued  
37  
46  
65 (Ref)  
16 17  
1
39  
3
65  
13  
9 16 17  
53  
80  
15  
32  
33  
67  
63  
40  
88  
47  
49  
25  
5
4
48  
24  
45  
8
7
31  
6
32  
33  
23  
45  
16  
24 (Ref)  
14  
44  
17  
12  
2
78  
TI4902a  
63  
78 (Ref)  
Pump Solenoid  
Cable Connections  
89  
86  
87  
83  
1
2
91  
90  
1
2
Downstroke solenoid is on the outside.  
Upstroke solenoid is on the inside.  
TI11262a  
28  
309909H  
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Parts  
Pump and Meter-based, Wall-mounted Air Spray Units, continued  
See page 27 for model numbers and descriptions.  
Ref.  
No.  
Ref.  
No.  
Part No.  
Description  
Qty.  
Part No.  
Description  
Qty.  
1
2
38  
113279  
PLUG, tube fitting;  
1
2
15D771  
234593  
FRAME, wall mount  
5/32 in. (4 mm) OD tube  
NUT, keps, hex hd; 10-24  
SCREW, cap, button hd;  
10-32 x 3/8 in. (10 mm)  
SCREW, machine; 1/4-20 x  
1-1/2 in. (38 mm)  
NUT, hex, flange hd; 1/4-20  
FITTING, air; 1/4 npt(m) x  
3/8 in. (10 mm) OD tube  
ELBOW; 1/4 npt(m) x  
3/8 in. (10 mm) OD tube  
FITTING, Y-adapter;  
1/4 in. (6 mm) OD tube  
ADAPTER; 3/8 in (10 mm) tube x  
1/4 in. (6 mm) tube  
1
MIX MANIFOLD; cst; carbon steel  
models only; see 310654  
MIX MANIFOLD; sst; stainless steel  
models only; see 310654  
CONTROL, air; see page 53  
ELBOW, pipe; 3/8 npt (mbe)  
ELBOW, street, 45°; 3/8 npt (mxf)  
UNION, adapter; 3/8 npsm(f) x  
3/8 npt(m)  
2
4
39  
40  
113505  
551787  
1
234451  
1
1
1
1
1
44  
114104  
3
4
5
6
287230  
109544  
116756  
155665  
7
1
45  
46  
115942  
113319  
1
1
1
47  
48  
49  
115841  
114158  
115743  
1
1
7
8
117629  
114316  
FILTER, air; 5 micron  
ELBOW; 3/8 npt(m) x 3/8 in.  
(10 mm) OD tube fitting  
FILTER, air; 40 micron  
1
1
9
10  
15D795  
248270  
PNEUMATIC CONTROL,  
intrinsically safe; see page 48  
USER INTERFACE; see page 52  
PUMP, UltraMix, cst; carbon steel  
models only; see 310671  
PUMP, UltraMix, sst; stainless steel  
models only; see 310671  
PLUG, pipe; 1/2 npt  
BRACKET, support, fluid manifold  
ELBOW; 1/2 npt(m) x  
3/8 in. (10 mm) OD tube fitting  
WASHER, lock; 1/4  
SCREW, cap, button hd;  
1/4-20 x 3/8 in. (10 mm)  
SCREW, machine, phillips;  
8-32 x 7/16 in. (11 mm)  
PLATE, side  
1
2 ft  
53  
56  
111763  
598095  
ELBOW; 1/4 npt (mbe)  
1
1
11  
12  
234620  
248570  
TUBE; nylon; 5/32 in. (4 mm) OD;  
clear; see pages 44, 46, and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
black; see pages 44, 46, and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
TUBE; nylon; 5/32 in. (4 mm) OD;  
TUBE; polyethylene; 3/8 in. (10 mm)  
OD; see pages 44, 46, and 47  
NIPPLE; 1/4 npsm x 1/4 npt  
FITTING, bulkhead  
ELBOW, street; 1/4 npt (m x f)  
TUBE; nylon; 1/4 in. (6 mm) OD;  
see pages 44, 46, and 47  
HOSE, fluid; 1/4 npsm (fbe); PTFE;  
1/4 in. (6 mm) ID; 18 in. (457 mm);  
see also pages 44 and 47  
BUSHING, strain relief  
BUSHING; 1/2 npt(m) x 1/4 npt(f)  
CHECK VALVE  
UNION, swivel; 1/4 npsm(f) x  
1/4 npt(m)  
HARNESS, wire  
SWITCH, air flow  
ADAPTER; 1/4 npsm x  
1/4 npt (mbe)  
METER, G3000; see 308778  
SHIELD, ESD, G3000  
2 ft  
2 ft  
2 ft  
57  
58  
59  
60  
054753  
054754  
054757  
590385  
1
248571  
1
1
2
13  
14  
15  
100361  
15D873  
C38211  
4.7  
ft  
2
1
1
4.2  
ft  
1
5
5
16  
17  
C19038  
112925  
63  
65  
67  
70  
162453  
104641  
100840  
054123  
4
20  
103196  
2
12  
4
21  
22  
23  
15D767  
119291  
113802  
SCREW, self-tapping  
78  
206966  
SCREW, hex hd, flanged;  
3/8-16 x 5/8 in. (16 mm)  
HOSE, air; nitrile; 1/2 in. (13 mm)  
ID; 1/2 npt (mbe); 18 in. (457 mm);  
see also pages 44, 46, and 47  
ELBOW, swivel; 1/2 npt(m) x  
1/2 npsm(f)  
CABLE, sensor; see Electrical  
HARNESS, connector; see Electri-  
LABEL, warning  
1
24  
220598  
1
1
1
1
79  
80  
83  
86  
195889  
100206  
501867  
114339  
1
2
2
25  
26  
27  
C19024  
15D607  
15D794  
1
1
1
87  
88  
89  
15D957  
119159  
166846  
1
2
2
2
28290331  
1
1
90  
91  
239716  
195283  
31  
32  
33  
101765  
100451  
115671  
GROMMET  
COUPLING; 1/8 npt (fbe)  
CONNECTOR; 1/8 npt(m) x  
1/4 in. (6 mm) OD tube  
Replacement Danger and Warning labels, tags, and cards  
are available at no cost.  
1
37  
244524  
GROUND WIRE  
309909H  
29  
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Parts  
Pump-based, Wall-mounted Air Spray Units  
Part No. 234599 Series A, carbon steel, intrinsically safe  
Part No. 234600 Series A, carbon steel, non-intrinsically safe  
Part No. 234601 Series A, stainless steel, intrinsically safe  
Part No. 234825 Series A, stainless steel, non-intrinsically safe  
10  
39  
11  
21, 28  
45  
22  
22  
20  
38  
79  
21  
TI4904b  
30  
309909H  
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Parts  
Pump-based, Wall-mounted Air Spray Units, continued  
37  
1
16  
17  
39  
17  
16  
15  
9
15  
32  
33  
40  
25  
49  
48  
3
5
13  
4
24  
7
8
45  
31  
6
32  
33  
24 (Ref)  
23  
12  
45  
16  
14  
44  
17  
78  
2
Pump Solenoid  
Cable Connections  
63  
2
1
78 (Ref)  
TI4905a  
1
Downstroke solenoid is on the outside.  
Upstroke solenoid is on the inside.  
2
TI11228a  
309909H  
31  
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Parts  
Pump-based, Wall-mounted Air Spray Units, continued  
See page 30 for model numbers and descriptions.  
Ref.  
No.  
Ref.  
No.  
Part No.  
Description  
Qty.  
Part No.  
Description  
Qty.  
1
2
26  
15D607  
CABLE, sensor; see Electrical  
HARNESS, connector; see Electri-  
LABEL, warning  
1
2
15D771  
234593  
FRAME, wall mount  
1
MIX MANIFOLD; cst; carbon steel  
models only; see 310654  
MIX MANIFOLD; sst; stainless steel  
models only; see 310654  
CONTROL, air; see page 53  
ELBOW, pipe; 3/8 npt (mbe); intrin-  
sically safe models only  
ELBOW; 3/8 npt(m) x 3/8 in.  
(10 mm) OD tube fitting; non-intrin-  
sically safe models only  
ELBOW, street, 45°; 3/8 npt (mxf);  
intrinsically safe models only  
UNION, adapter; 3/8 npsm(f) x  
3/8 npt(m); intrinsically safe models  
only  
FILTER, air; 5 micron; intrinsically  
safe models only  
ELBOW; 3/8 npt(m) x 3/8 in.  
(10 mm) OD tube fitting;  
intrinsically safe models only  
FILTER, air; 40 micron  
PNEUMATIC CONTROL;  
intrinsically safe models only;  
see page 48  
PNEUMATIC CONTROL; non-intrin-  
sically safe models only; see page  
2
27  
15D794  
1
234451  
1
2
2
28290331  
31  
32  
1
1
101765  
100451  
GROMMET  
3
4
287230  
109544  
COUPLING; 1/8 npt (fbe);  
intrinsically safe models only  
COUPLING; 1/8 npt (fbe);  
non-intrinsically safe models only  
CONNECTOR; 1/8 npt(m) x  
1/4 in. (6 mm) OD tube;  
intrinsically safe models only  
CONNECTOR; 1/8 npt(m) x  
1/4 in. (6 mm) OD tube; non-intrinsi-  
cally safe models only  
1
2
1
100451  
115671  
114316  
33  
1
1
5
6
116756  
155665  
1
115671  
1
2
1
1
37  
38  
244524  
113279  
GROUND WIRE  
PLUG, tube fitting;  
7
8
117629  
114316  
5/32 in. (4 mm) OD tube  
NUT, keps, hex hd; 10-24  
SCREW, cap, button hd;  
10-32 x 3/8 in. (10 mm)  
SCREW, machine; 1/4-20 x  
1-1/2 in. (38 mm)  
NUT, hex, flange hd; 1/4-20  
FITTING, Y-adapter;  
1/4 in. (6 mm) OD tube  
ADAPTER; 3/8 in (10 mm) tube x  
1/4 in. (6 mm) tube  
TUBE; nylon; 5/32 in. (4 mm) OD;  
clear; see pages 44 and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
black; see pages 44 and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
red; see pages 44 and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
green; see pages 44 and 47  
TUBE; polyethylene; 3/8 in. (10 mm)  
OD; see pages 44 and 47  
NIPPLE; 1/4 npsm x 1/4 npt  
TUBE; nylon; 1/4 in. (6 mm) OD;  
see pages 44 and 47  
2
4
39  
40  
113505  
551787  
1
1
9
10  
15D795  
248270  
1
44  
114104  
7
2
45  
48  
115942  
114158  
1
248316  
2
2 ft  
2 ft  
2 ft  
2 ft  
49  
56  
57  
58  
59  
60  
115743  
598095  
054753  
054754  
054757  
590385  
1
2
11  
12  
234620  
248570  
USER INTERFACE; see page 52  
PUMP, UltraMix, cst; carbon steel  
models only; see 310671  
PUMP, UltraMix, sst; stainless steel  
models only; see 310671  
PLUG, pipe; 1/2 npt  
2
248571  
1
1
2
13  
14  
15  
100361  
15D873  
C38211  
BRACKET, support, fluid manifold  
ELBOW; 1/2 npt(m) x  
3/8 in. (10 mm) OD tube fitting  
WASHER, lock; 1/4  
SCREW, cap, button hd;  
1/4-20 x 3/8 in. (10 mm)  
SCREW, machine, phillips;  
8-32 x 7/16 in. (11 mm)  
6.7  
ft  
2
4.2  
ft  
2
5
5
16  
17  
C19038  
112925  
63  
70  
162453  
054123  
4
20  
103196  
2
12  
8
78  
79  
206966  
195889  
HOSE, fluid; 1/4 npsm (fbe); PTFE;  
1/4 in. (6 mm) ID; 18 in. (457 mm);  
see also pages 44 and 47  
BUSHING, strain relief  
21  
22  
23  
15D767  
119291  
113802  
PLATE, side  
SCREW, self-tapping  
SCREW, hex hd, flanged;  
3/8-16 x 5/8 in. (16 mm)  
HOSE, air; nitrile; 1/2 in. (13 mm)  
ID; 1/2 npt (mbe); 18 in. (457 mm);  
see also pages 44 and 47  
ELBOW, swivel; 1/2 npt(m) x  
1/2 npsm(f)  
2
1
1
24  
25  
220598  
C19024  
Replacement Danger and Warning labels, tags, and cards  
are available at no cost.  
32  
309909H  
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Parts  
Meter-based, Wall-mounted High Pressure Units  
Part No. 234618 Series A, carbon steel  
Part No. 234619 Series A, stainless steel  
10  
39  
11  
21, 28  
45  
22  
22  
20  
38  
TI4917a  
21  
309909H  
33  
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Parts  
Meter-based, Wall-mounted High Pressure Units, continued  
46  
37  
65 (Ref)  
1
39  
16  
17  
65  
9
16 17  
3
80  
67  
63  
53  
32  
33  
40  
88  
25  
47  
5
4
24  
45  
31  
8
7
1
6
32  
33  
45  
16  
14  
44  
24 (Ref)  
17  
2
89  
86  
87  
83  
1
Wires to circuit board; see Electrical Schematic, page 22.  
TI4918a  
91  
90  
34  
309909H  
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Parts  
Meter-based, Wall-mounted High Pressure Units, continued  
See page 33 for model numbers and descriptions.  
Ref.  
No.  
Ref.  
No.  
Part No. Description  
Qty.  
2 ft  
Part No. Description  
Qty.  
1
56  
57  
58  
59  
60  
598095 TUBE; nylon; 5/32 in. (4 mm) OD;  
clear; see pages 46 and 47  
054753 TUBE; nylon; 5/32 in. (4 mm) OD;  
black; see pages 46 and 47  
054754 TUBE; nylon; 5/32 in. (4 mm) OD; red;  
054757 TUBE; nylon; 5/32 in. (4 mm) OD;  
green; see pages 46 and 47  
590385 TUBE; polyethylene; 3/8 in. (10 mm)  
162453 NIPPLE; 1/4 npsm x 1/4 npt  
104641 FITTING, bulkhead  
100840 ELBOW, street; 1/4 npt (m x f)  
054123 TUBE; nylon; 1/4 in. (6 mm) OD; see  
100206 BUSHING; 1/2 npt(m) x 1/4 npt(f)  
501867 CHECK VALVE  
1
2
15D771 FRAME, wall mount  
234593 MANIFOLD, mix (234618); cst;  
see 310654  
234451 MANIFOLD, mix (234619); sst;  
see 310654  
287231 CONTROL, air; see page 53  
109544 ELBOW, pipe; 3/8 npt (mbe)  
116756 ELBOW, street, 45°; 3/8 npt (m x f)  
155665 UNION, adapter; 3/8 npsm(f) x  
3/8 npt(m)  
117629 FILTER, air; 5 micron  
114316 ELBOW; 3/8 npt(m) x  
3/8 in. (10 mm) OD tube  
15D795 FILTER, air; 40 micron  
248270 PNEUMATIC CONTROL,  
intrinsically safe; see page 54  
234620 USER INTERFACE; see page 52  
15D873 BRACKET, support, fluid manifold  
C19038 WASHER, lock; 1/4  
112925 SCREW, cap; 1/4-20 x  
3/8 in. (10 mm)  
1
2 ft  
2 ft  
2 ft  
1
1
1
1
1
3
4
5
6
3.5  
ft  
1
1
1
63  
65  
67  
70  
1
1
7
8
4 ft  
1
1
9
10  
1
2
2
80  
83  
86  
1
1
5
5
11  
14  
16  
17  
114339 UNION, swivel; 1/4 npsm(f) x  
1/4 npt(m)  
15D957 HARNESS, wire  
119159 SWITCH, air flow  
166846 ADAPTER; 1/4 npsm x  
1/4 npt (mbe)  
1
1
2
87  
88  
89  
4
20  
103196 SCREW, machine, phillips;  
8-32 x 7/16 in. (11 mm)  
15D767 PLATE, side  
119291 SCREW, self-tapping  
220598 HOSE, air; nitrile; 1/2 in. (13 mm) ID;  
1/2 npt (mbe); 18 in. (457 mm); see  
2
2
90  
91  
239716 METER, G3000; see 308778  
195283 SHIELD, ESD, G3000  
2
12  
1
21  
22  
24  
Replacement Danger and Warning labels, tags, and cards  
are available at no cost.  
1
25  
C19024 ELBOW, swivel; 1/2 npt(m) x  
1/2 npsm(f)  
1
2
2
2
28290331 LABEL, warning  
31  
32  
33  
101765 GROMMET  
100451 COUPLING; 1/8 npt (fbe)  
115671 CONNECTOR; 1/8 npt(m) x  
1/4 in. (6 mm) OD tube  
1
2
37  
38  
244524 GROUND WIRE  
113279 PLUG, tube fitting;  
5/32 in. (4 mm) OD tube  
2
4
39  
40  
113505 NUT, keps, hex hd; 10-24  
551787 SCREW, cap, button hd;  
10-32 x 3/8 in. (10 mm)  
1
44  
114104 SCREW, machine; 1/4-20 x  
1-1/2 in. (38 mm)  
7
1
45  
46  
115942 NUT, hex, flange hd; 1/4-20  
113319 FITTING, air; 1/4 npt(m) x  
3/8 in. (10 mm) OD tube  
1
1
47  
53  
115841 ELBOW; 1/4 npt(m) x  
3/8 in. (10 mm) OD tube  
111763 ELBOW; 1/4 npt (mbe)  
309909H  
35  
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Parts  
Pump-based, Wall-mounted High Pressure Units  
Part No. 234606 Series A, HydraMix 500 carbon steel, intrinsically safe  
Part No. 234607 Series A, HydraMix 500 carbon steel, non-intrinsically safe  
Part No. 234609 Series A, HydraMix 600 carbon steel, intrinsically safe  
Part No. 234610 Series A, HydraMix 600 carbon steel, non-intrinsically safe  
Part No. 234612 Series A, HydraMix 700 carbon steel, intrinsically safe  
Part No. 234608 Series A, HydraMix 500 stainless steel, intrinsically safe  
Part No. 234826 Series A, HydraMix 500 stainless steel, non-intrinsically safe  
Part No. 234611 Series A, HydraMix 600 stainless steel, intrinsically safe  
Part No. 234827 Series A, HydraMix 600 stainless steel, non-intrinsically safe  
Part No. 234613 Series A, HydraMix 700 stainless steel, intrinsically safe  
10  
39  
11  
45  
22  
21, 28  
22  
20  
38  
79  
21  
TI4910b  
36  
309909H  
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Parts  
Pump-based, Wall-mounted High Pressure Units, continued  
37  
1
16 17  
39  
17  
16  
9
96  
94  
95  
15  
15  
32  
33  
5
40  
25  
3
13  
4
7
24  
12  
45  
31  
6
93  
68  
69  
8
23  
24 (Ref)  
45  
16  
14  
44  
32  
34  
33  
17  
15  
34  
2
50  
50  
Detail of B Side  
Muffler  
35  
36  
TI4911b  
Pump Solenoid  
Cable Connections  
2
1
1
2
Downstroke solenoid connection.  
Upstroke solenoid connection.  
TI5294a  
309909H  
37  
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Parts  
Pump-based, Wall-mounted High Pressure Units, continued  
See page 36 for model numbers and descriptions.  
Ref.  
No.  
Ref.  
No.  
Part No.  
Description  
Qty.  
12  
8
Part No.  
Description  
Qty.  
1
22  
23  
119291  
113802  
SCREW, self-tapping  
1
2
15D771  
234593  
FRAME, wall mount  
1
SCREW, hex hd, flanged;  
3/8-16 x 5/8 in. (16 mm)  
HOSE, air; nitrile; 1/2 in. (13 mm)  
ID; 1/2 npt (mbe); 18 in. (457 mm);  
see also pages 45 and 47  
ELBOW, swivel; 1/2 npt(m) x  
1/2 npsm(f)  
CABLE, sensor; see Electrical  
HARNESS, connector; see Electri-  
LABEL, warning  
MIX MANIFOLD; cst; carbon steel  
models only; see 310654  
MIX MANIFOLD; sst; stainless steel  
models only; see 310654  
CONTROL, air; see page 53  
ELBOW, pipe; 3/8 npt (mbe); intrin-  
sically safe models only  
ELBOW; 3/8 npt(m) x 3/8 in.  
(10 mm) OD tube fitting; non-intrin-  
sically safe models only  
ELBOW, street, 45°; 3/8 npt (mxf);  
intrinsically safe models only  
UNION, adapter; 3/8 npsm(f) x  
3/8 npt(m); intrinsically safe models  
only  
1
1
24  
220598  
234451  
1
1
3
4
287230  
109544  
1
2
2
25  
26  
27  
C19024  
15D607  
15D794  
1
114316  
1
1
5
6
116756  
155665  
1
2
2
28290331  
31  
32  
101765  
100451  
GROMMET  
COUPLING; 1/8 npt (fbe); intrinsi-  
cally safe models only  
1
2
1
1
100451  
115671  
COUPLING; 1/8 npt (fbe);  
non-intrinsically safe models only  
CONNECTOR; 1/8 npt(m) x  
1/4 in. (6 mm) OD tube;  
intrinsically safe models only  
CONNECTOR; 1/8 npt(m) x  
1/4 in. (6 mm) OD tube; non-intrinsi-  
cally safe models only  
7
8
117629  
114316  
FILTER, air; 5 micron; intrinsically  
safe models only  
ELBOW; 3/8 npt(m) x  
3/8 in. (10 mm) OD tube fitting;  
intrinsically safe models only  
FILTER, air; 40 micron  
PNEUMATIC CONTROL;  
intrinsically safe models only;  
see page 48  
33  
1
1
1
115671  
9
10  
15D795  
248270  
2
2
34  
35  
15D966  
15E020  
BRACKET, muffler  
1
FITTING, compression; cst;  
carbon steel models only;  
1/4 npt(m) x 1/2 in. (13 mm) tube  
FITTING, compression; sst;  
stainless steel models only;  
1/4 npt(m) x 1/2 in. (13 mm) tube  
ELBOW, compression; cst;  
carbon steel models only;  
3/8 npt(m) x 1/2 in. (13 mm) tube  
ELBOW, compression; sst;  
stainless steel models only;  
3/8 npt(m) x 1/2 in. (13 mm) tube  
GROUND WIRE  
248316  
PNEUMATIC CONTROL; non-intrin-  
sically safe models only; see page  
2
2
2
1
2
15E021  
15E018  
15E019  
11  
12  
234620  
248572  
USER INTERFACE; see page 52  
PUMP, HydraMix 500, cst; 234606  
and 234607; see 310672  
PUMP, HydraMix 500, sst; 234608  
and 234826; see 310672  
PUMP, HydraMix 600, cst; 234609  
and 234610; see 310672  
PUMP, HydraMix 600, sst; 234611  
and 234827; see 310672  
PUMP, HydraMix 700, cst; 234612;  
see 310672  
PUMP, HydraMix 700, sst; 234613;  
see 310672  
PLUG, pipe; 1/2 npt  
BRACKET, support, fluid manifold  
ELBOW; 1/2 npt(m) x  
1/2 in. (13 mm) OD tube fitting  
2
2
2
2
2
36  
248573  
248574  
248575  
248576  
248577  
1
2
37  
38  
244524  
113279  
PLUG, tube fitting;  
5/32 in. (4 mm) OD tube  
NUT, keps, hex hd; 10-24  
SCREW, cap, button hd;  
10-32 x 3/8 in. (10 mm)  
TUBE, fluid, A component; see  
TUBE, fluid, B component; see  
SCREW, machine; 1/4-20 x  
1-1/2 in. (38 mm)  
2
4
39  
40  
113505  
551787  
1
1
3
13  
14  
15  
100361  
15D873  
114110  
1
1
1
7
42  
43  
44  
45  
15D998  
15D999  
114104  
115942  
5
5
16  
17  
C19038  
112925  
WASHER, lock; 1/4  
SCREW, cap, button hd;  
1/4-20 x 3/8 in. (10 mm)  
SCREW, machine, phillips;  
8-32 x 7/16 in. (11 mm)  
4
2
20  
21  
103196  
15D767  
NUT, hex, flange hd; 1/4-20  
PLATE, side  
38  
309909H  
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Parts  
Ref.  
No.  
Ref.  
No.  
Part No.  
Description  
Qty.  
2
2 ft  
Part No.  
Description  
Qty.  
1
50  
56  
102656  
598095  
MUFFLER  
69  
100081  
BUSHING, pipe; 1/2 npt(m) x  
3/8 npt(f)  
TUBE; nylon; 1/4 in. (6 mm) OD;  
see pages 45 and 47  
BUSHING, strain relief  
SCREW, hex hd, flange; 1/4-20 x  
3/4 in. (19 mm)  
COVER, sensor; non-intrinsically  
safe carbon steel models only  
O-RING; non-intrinsically safe car-  
bon steel models only  
BUSHING, strain relief;  
non-intrinsically safe carbon steel  
models only  
TUBE; nylon; 5/32 in. (4 mm) OD;  
clear; see pages 45 and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
black; see pages 45 and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
red; see pages 45 and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
green; see pages 45 and 47  
TUBE; polyethylene; 3/8 in. (10 mm)  
OD; see pages 45 and 47  
TUBE; nylon; 1/2 in. (13 mm) OD;  
see pages 45 and 47  
4 ft  
70  
054123  
2 ft  
2 ft  
2 ft  
57  
58  
59  
60  
61  
68  
054753  
054754  
054757  
590385  
061134  
114129  
2
4
79  
93  
195889  
113796  
2
2
2
94  
95  
96  
15A818  
C20272  
15E383  
0.7  
ft  
5.2  
ft  
1
FITTING; 3/8 npt(m) x  
1/2 in. (13 mm) OD tube fitting  
Replacement Danger and Warning labels, tags, and cards  
are available at no cost.  
309909H  
39  
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Parts  
Pump and Meter-based, Wall-mounted High Pressure Units  
Part No. 234602 Series A, HydraMix 500 carbon steel pump and G3000 Meter  
Part No. 234603 Series A, HydraMix 500 stainless steel pump and G3000 Meter  
Part No. 234604 Series A, HydraMix 600 carbon steel pump and G3000 Meter  
Part No. 234605 Series A, HydraMix 600 stainless steel pump and G3000 Meter  
10  
39  
11  
45  
21, 28  
22  
22  
20  
38  
79  
21  
TI4907b  
40  
309909H  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Parts  
Pump and Meter-based, Wall-mounted High Pressure Units, continued  
46  
37  
65 (Ref)  
1
16 17  
39  
65  
3
67  
13  
80  
17  
16  
15  
9
32  
33  
53  
88  
40  
25  
5
47  
4
24  
12  
63  
7
45  
31  
6
93  
68  
8
23  
69  
34  
45  
17 16  
14  
44  
32  
24 (Ref)  
33  
2
50  
35  
36  
89  
86  
TI4908a  
83  
Pump Solenoid  
Cable Connections  
2
1
91  
90  
87  
1
2
Downstroke solenoid connection.  
Upstroke solenoid connection.  
TI5294a  
309909H  
41  
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Parts  
Pump and Meter-based, Wall-mounted High Pressure Units, continued  
See page 40 for model numbers and descriptions.  
Ref.  
No.  
Ref.  
No.  
Part No.  
Description  
Qty.  
Part No.  
Description  
Qty.  
1
2
33  
115671  
CONNECTOR; 1/8 npt(m) x  
1/4 in. (6 mm) OD tube  
BRACKET, muffler  
1
2
15D771  
234593  
FRAME, wall mount  
1
MIX MANIFOLD; cst; carbon steel  
models only; see 310654  
MIX MANIFOLD; sst; stainless steel  
models only; see 310654  
CONTROL, air; see page 53  
ELBOW, pipe; 3/8 npt (mbe)  
ELBOW, street, 45°; 3/8 npt (mxf)  
UNION, adapter; 3/8 npsm(f) x  
3/8 npt(m)  
FILTER, air; 5 micron  
ELBOW; 3/8 npt(m) x  
3/8 in. (10 mm) OD tube fitting  
FILTER, air; 40 micron  
PNEUMATIC CONTROL,  
intrinsically safe; see page 48  
USER INTERFACE; see page 52  
PUMP, HydraMix 500, cst; 234602;  
see 310672  
PUMP, HydraMix 500, sst; 234603;  
see 310672  
PUMP, HydraMix 600, cst; 234604;  
see 310672  
PUMP, HydraMix 600, sst; 234605;  
see 310672  
PLUG, pipe; 1/2 npt  
BRACKET, support, fluid manifold  
ELBOW; 1/2 npt(m) x  
1
1
34  
35  
15D966  
15E020  
1
FITTING, compression; cst;  
carbon steel models only;  
1/4 npt(m) x 1/2 in. (13 mm) tube  
FITTING, compression; sst;  
stainless steel models only;  
1/4 npt(m) x 1/2 in. (13 mm) tube  
ELBOW, compression; cst;  
carbon steel models only;  
3/8 npt(m) x 1/2 in. (13 mm) tube  
ELBOW, compression; sst;  
stainless steel models only;  
3/8 npt(m) x 1/2 in. (13 mm) tube  
GROUND WIRE  
234451  
1
1
1
1
3
4
5
6
287230  
109544  
116756  
155665  
1
1
1
15E021  
15E018  
15E019  
36  
1
1
7
8
117629  
114316  
1
1
9
10  
15D795  
248270  
1
2
37  
38  
244524  
113279  
PLUG, tube fitting;  
1
1
11  
12  
234620  
248572  
5/32 in. (4 mm) OD tube  
NUT, keps, hex hd; 10-24  
SCREW, cap, button hd;  
10-32 x 3/8 in. (10 mm)  
TUBE, fluid, A component; see  
SCREW, machine; 1/4-20 x  
1-1/2 in. (38 mm)  
NUT, hex, flange hd; 1/4-20  
FITTING, air; 1/4 npt(m) x  
3/8 in. (10 mm) OD tube  
ELBOW; 1/4 npt(m) x  
2
4
39  
40  
113505  
551787  
1
1
1
248573  
248574  
248575  
1
1
42  
44  
15D998  
114104  
7
1
45  
46  
115942  
113319  
1
1
1
13  
14  
15  
100361  
15D873  
114110  
1
47  
115841  
1/2 in. (13 mm) OD tube fitting  
WASHER, lock; 1/4  
3/8 in. (10 mm) OD tube  
MUFFLER  
ELBOW; 1/4 npt (mbe)  
5
5
16  
17  
C19038  
112925  
1
1
2 ft  
50  
53  
56  
102656  
111763  
598095  
SCREW, cap, button hd;  
1/4-20 x 3/8 in. (10 mm)  
SCREW, machine, phillips;  
8-32 x 7/16 in. (11 mm)  
PLATE, side  
TUBE; nylon; 5/32 in. (4 mm) OD;  
clear; see pages 45, 46, and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
black; see pages 45, 46, and 47  
TUBE; nylon; 5/32 in. (4 mm) OD;  
TUBE; nylon; 5/32 in. (4 mm) OD;  
TUBE; polyethylene; 3/8 in. (10 mm)  
OD; see pages 45, 46, and 47  
TUBE; nylon; 1/2 in. (13 mm) OD;  
see pages 45, 46, and 47  
NIPPLE; 1/4 npsm x 1/4 npt  
FITTING, bulkhead  
4
20  
103196  
2 ft  
2 ft  
2 ft  
57  
58  
59  
60  
61  
054753  
054754  
054757  
590385  
061134  
2
12  
4
21  
22  
23  
15D767  
119291  
113802  
SCREW, self-tapping  
SCREW, hex hd, flanged;  
3/8-16 x 5/8 in. (16 mm)  
HOSE, air; nitrile; 1/2 in. (13 mm)  
ID; 1/2 npt (mbe); 18 in. (457 mm);  
see also pages 45, 46, and 47  
ELBOW, swivel; 1/2 npt(m) x  
1/2 npsm(f)  
CABLE, sensor; see Electrical  
HARNESS, connector; see Electri-  
LABEL, warning  
1
24  
220598  
4.6  
ft  
1 ft  
1
1
1
25  
26  
27  
C19024  
15D607  
15D794  
1
1
1
1
63  
65  
67  
68  
162453  
104641  
100840  
114129  
ELBOW, street; 1/4 npt (m x f)  
FITTING; 3/8 npt(m) x  
1/2 in. (13 mm) OD tube fitting  
BUSHING, pipe; 1/2 npt(m) x  
3/8 npt(f)  
1
2
2
28290331  
31  
32  
101765  
100451  
GROMMET  
COUPLING; 1/8 npt (fbe)  
1
69  
100081  
42  
309909H  
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Parts  
Ref.  
No.  
Part No.  
Description  
Qty.  
3.5  
ft  
70  
054123  
TUBE; nylon; 1/4 in. (6 mm) OD;  
BUSHING, strain relief  
BUSHING; 1/2 npt(m) x 1/4 npt(f)  
CHECK VALVE  
1
1
1
1
79  
80  
83  
86  
195889  
100206  
501867  
114339  
UNION, swivel; 1/4 npsm(f) x  
1/4 npt(m)  
1
1
1
87  
88  
89  
15D957  
119159  
166846  
HARNESS, wire  
SWITCH, air flow  
ADAPTER; 1/4 npsm x  
1/4 npt (mbe)  
1
1
90  
91  
239716  
195283  
METER, G3000; see 308778  
SHIELD, ESD, G3000  
Replacement Danger and Warning labels, tags, and cards  
are available at no cost.  
309909H  
43  
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Parts  
Tube Connections, Low Pressure Pumps  
Find the keys on the drawing to ensure proper connections.  
Ref.  
No.  
Length,  
in. (mm)  
Ref.  
No.  
Length,  
in. (mm)  
Key Description  
Key Description  
G2 Gun Air Regulator (74) Output  
60  
30 (762)  
18 (457)  
18 (457)  
18 (457)  
17 (432)  
21 (533)  
2 (51)  
A1 Dispense Valve A OFF  
A2 Dispense Valve A ON  
B1 Dispense Valve B OFF  
B2 Dispense Valve B ON  
C1 Air to Pneumatic Control (10)  
D1 Air Filter (9) Drain Tube  
D2 Air Filter (7) Drain Tube  
G1 Gun Air Regulator (74) Input  
56  
57  
59  
58  
60  
70  
70  
60  
24 (610)  
24 (610)  
24 (610)  
24 (610)  
8 (203)  
24 (610)  
18 (457)  
31 (787)  
L1  
L2  
Fluid Line, Pump A to Dispense Valve A 78  
Fluid Line, Pump B to Dispense Valve B 78  
M1 Air Filter (9) to Air Control (3)  
24  
60  
60  
70  
70  
P1  
P2  
S1  
S2  
Pump A Input Air  
Pump B Input Air  
Pump A Solenoid Inputs (2 tubes)  
Pump B Solenoid Inputs (2 tubes)  
2 (51)  
P2  
P1  
G2  
C1  
G1  
G1  
M1  
D1  
M1  
D2  
P2  
P1  
B Side  
A Side  
S2  
S1  
C1  
D1 D2  
L1  
B2  
A2  
L2  
B1 A1  
B1  
B2  
A1  
A2  
L2  
L1  
TI5278a  
44  
309909H  
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Parts  
Tube Connections, High Pressure Pumps  
Find the keys on the drawing to ensure proper connections.  
Ref.  
No.  
Length,  
in. (mm)  
Ref.  
No.  
Length,  
in. (mm)  
Key Description  
Key Description  
L1  
Fluid Line, Pump A to Dispense Valve A 42  
molded  
tube  
molded  
tube  
18 (457)  
18 (457)  
24 (610)  
A1 Dispense Valve A OFF  
A2 Dispense Valve A ON  
B1 Dispense Valve B OFF  
B2 Dispense Valve B ON  
C1 Air to Pneumatic Control (10)  
D1 Air Filter (9) Drain Tube  
D2 Air Filter (7) Drain Tube  
56  
57  
59  
58  
60  
70  
70  
61  
61  
24 (610)  
24 (610)  
24 (610)  
24 (610)  
8 (203)  
24 (610)  
18 (457)  
8 (203)  
L2  
Fluid Line, Pump B to Dispense Valve B 43  
M1 Air Filter (9) to Air Control (3)  
P1  
P2  
24  
61  
61  
Pump A Input Air  
Pump B Input Air  
E1  
E2  
Pump A Exhaust  
Pump B Exhaust  
12 (305)  
P2  
P1  
C1  
M1  
D1  
M1  
D2  
P2  
P1  
B Side  
A Side  
C1  
E2  
D1  
A2  
D2 E1  
B2  
B1 A1  
L1  
L2  
B1  
B2  
A1  
A2  
L1  
L2  
TI5279a  
309909H  
45  
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Parts  
Tube Connections, Meters  
Find the keys on the drawing to ensure proper connections. This page shows a unit with meters on both sides. If your  
model is a pump/meter combination unit, also refer to pages 44 and 45 for additional connections.  
Ref.  
No.  
Length,  
in. (mm)  
Ref.  
No.  
Length,  
in. (mm)  
Key Description  
Key Description  
D1 Air Filter (9) Drain Tube  
D2 Air Filter (7) Drain Tube  
G1 Gun Air Flow Switch (88) to Gun Air Line 60  
M1 Air Filter (9) to Air Control (3) 24  
70  
70  
24 (610)  
18 (457)  
30 (762)  
18 (457)  
A1 Dispense Valve A OFF  
A2 Dispense Valve A ON  
B1 Dispense Valve B OFF  
B2 Dispense Valve B ON  
C1 Air to Pneumatic Control (10)  
56  
57  
59  
58  
60  
24 (610)  
24 (610)  
24 (610)  
24 (610)  
8 (203)  
G1  
G1  
C1  
M1  
D1  
P2  
M1  
D2  
C1  
D1  
D2  
B2  
A2  
A Side  
B Side  
B1 A1  
B1  
B2  
A1  
A2  
TI5280a  
46  
309909H  
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Parts  
Pneumatic Schematic  
MOTOR  
DOWN  
MOTORA  
B
DOWN  
MOTOR  
UP  
MOTORA  
PUMPBUP, 12 VDC  
PUMPAUP, 12 VDC  
B
UP  
PUMP DOWN, 12 VDC  
PUMP  
DOWN, 12 VDC  
B
A
AIR EXHAUST,  
1/2 TUBE X 24" LONG  
MANIFOLD  
12 VDC  
SOLENOID  
AIR SUPPLY  
GAUGE  
METERING  
A
B
VALVE  
POSITION 1  
AIR REGULATOR  
12 VDC  
SOLENOID  
METERING  
VALVE  
TO MANIFOLD  
3/8 TUBE  
110 PSI  
RELIEF  
VALVE  
POSITION 2  
POSITION 3  
(OPEN FOR OPT. CIRCULATION ACCESSORY SOLENOID)  
3/8 AIR FILTER  
AUTO DRAIN  
5 MICRON  
GAUGE  
POSITION 4  
(OPEN WITH BLANK PLATE)  
3/4 AIR  
FILTER  
AUTO DRAIN  
20 MICRON  
3/4" BALL VALVE  
BLEED TYPE  
AIR  
REGULATOR  
SET @ 22 PSI  
TURBINE / POWER SUPPLY  
RELIEF VALVE  
26 PSI FACTORY SET  
309909H  
47  
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Parts  
248270 Intrinsically Safe Pneumatic Control  
Ref.  
Ref.  
No. Part No. Description  
Qty.  
No. Part No. Description  
Qty.  
1
306q 112512 • WIRE FERRULE, orange  
4
301* 248349 CIRCUIT BOARD, main  
302 100035 SCREW, machine, phillips;  
8-32 x 5/16 in. (8 mm)  
(not shown)  
8
306r 117369 • CONNECTOR, 12 position  
306s 150278 • ADAPTER, 1/4 x 1/8 npt  
306t 117480 • SAFETY RELIEF VALVE,  
26 psi (179 kPa, 1.8 bar)  
1
1
1
1
304 245854 MODULE, alternator;  
includes items 304a-304e  
304a 193154 • GASKET; LDPE foam  
304b 15A853 • WIRE HARNESS  
304c 111225 • ELBOW; 1/8 npt(m) x  
3/8 in. (10 mm) tube fitting  
304d 114380 • SCREW; M5 x 25  
304e 249254 • TURBINE ALTERNATOR  
305 109466 NUT, lock, w/nylon insert; 8-32  
306 248268 MODULE, solenoid, IS;  
includes items 306a-306u  
306a 15A822 • MANIFOLD  
306b 117356 • VALVE, 12 VDC, IS  
306c 114263 • FITTING; 1/8 npt x  
5/32 in. (4 mm) tube  
306d 156971 • NIPPLE; 1/4 npt  
306e 115243 • AIR REGULATOR; 1/4 npt  
306f 115841 • ELBOW; 1/4 npt x  
3/8 in. (10 mm) tube fitting  
306g 160701 • ELBOW, street; 1/8 npt(m x f)  
306h 108190 • GAUGE  
306j 15A798 • GASKET, neoprene  
306k 15A799 • GASKET, neoprene  
306m 110207 • ELBOW; 1/8 npt (mbe)  
306n 104765 • PLUG, pipe; 1/8 ptf  
306p 517449 • MUFFLER  
306u 552183 • PLATE  
2
1
2
2
1
1
2
307 15A800 GASKET; neoprene  
308 195889 BUSHING, strain relief  
309 106084 SCREW, machine;  
M5 x 0.8; 10 mm  
310 C12508 TUBE, nylon, black; 3/8 in. (10  
mm) OD  
4
1
2
1 ft  
1
1
1
1
1
1
1
1 ft  
1
1
1
311 113505 NUT, keps; 10-24  
312 104029 CLAMP, ground  
1
2
6
313 15A849 HARNESS, wire, alarm  
314 117442 CONNECTOR, plug, 18 position  
315 15B090 WIRE, grounding, door  
317 111307 WASHER, lock, external tooth; M5  
318 065213 WIRE, copper  
320 118132 TERMINAL, lug, lockwasher  
321 118129 SPACER  
322 114213 HARNESS, connector  
323 246899 CIRCUIT BOARD  
324 112512 FERRULE, wire  
1
1
3
1
1
1
1
1
6
1
1
2
1
330 119163 CONNECTOR, plug, 8 position  
*
When ordering 248349 as a replacement part, you must also order a data download kit to program the circuit  
board to the specific machine configuration. Order Kit 248403 for hazardous locations or Kit 248404 for non-haz-  
ardous locations. See manual 309623 for further instructions.  
48  
309909H  
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Parts  
248270 Intrinsically Safe Pneumatic Control, continued  
Alternator Module (304) Detail  
307  
330  
320  
302, 321  
314  
304a  
304d  
323  
301  
311  
304  
304e  
315  
306  
304b  
310  
304c  
A B  
322  
313  
308  
TI4561b  
306g  
306f  
306h  
Solenoid Module (306) Detail  
306f  
306d  
306e  
306s  
306a  
306n  
306p  
306m  
306t  
A
B
306n  
306n  
306f  
306k  
306j  
306b  
TI4558a  
306c  
306u  
309909H  
49  
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Parts  
248316 Non-intrinsically Safe Pneumatic Control  
Ref.  
Ref.  
No. Part No. Description  
Qty.  
1
No. Part No. Description  
Qty.  
1
308 195889 BUSHING, strain relief  
309 106084 SCREW, machine;  
M5 x 0.8; 10 mm  
311 113505 NUT, keps; 10-24  
312 104029 CLAMP, ground  
313 15A849 HARNESS, wire, alarm  
314 117442 CONNECTOR, plug, 18 position  
315 15B090 WIRE, grounding, door  
317 111307 WASHER, lock, external tooth; M5  
318 065213 WIRE, copper; 18 AWG;  
green w/yellow stripe  
301* 248349 CIRCUIT BOARD  
302 100035 SCREW, machine, phillips;  
8-32 x 5/16 in. (8 mm)  
305 109466 NUT, lock, w/nylon insert; 8-32  
306 248297 MODULE, solenoid, non-IS  
306a 15A822 • MANIFOLD  
306b 117357 • VALVE, 12 VDC, non-IS  
306c 114263 • FITTING; 1/8 npt x 5/32” (4 mm)  
tube  
2
8
1
1
1
1
1
2
1
1
2
6
1
1 ft  
306d 100721 • PLUG, pipe  
2
1
306f 115841 • ELBOW, swivel; 1/4 npt x  
3/8” (9.5 mm) tube  
306j 15A798 • GASKET, neoprene  
306k 15A799 • GASKET, neoprene  
306n 104765 • PLUG, pipe; 1/8 ptf  
306p 517449 • MUFFLER  
1
1
6
1
4
1
1
1
1
2
1
1
1
320 118132 TERMINAL, lug, lockwasher  
321 118129 SPACER  
322 114213 HARNESS, connector  
323 246899 CIRCUIT BOARD  
324 112512 FERRULE, wire (not shown)  
325 15D891 WIRE HARNESS  
306q 112512 • WIRE FERRULE, orange  
(not shown)  
306r 117369 • CONNECTOR, 12 position  
306u 552183 • PLATE  
307 15A800 GASKET; neoprene  
1
2
1
328 248325 POWER SUPPLY, 12 VDC  
330 119163 CONNECTOR, plug, 8 position  
*
When ordering 248349 as a replacement part, you must also order a data download kit to program the circuit  
board to the specific machine configuration. Order Kit 248403 for hazardous locations or Kit 248404 for non-haz-  
ardous locations. See manual 309623 for further instructions.  
50  
309909H  
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Parts  
248316 Non-intrinsically Safe Pneumatic Control, continued  
307  
330  
301  
317  
312  
318  
323  
306r  
321  
328  
309  
315  
320  
302  
306  
314  
311  
A B  
305  
322  
TI4567b  
313  
Solenoid Module (306) Detail  
308  
306n  
306a  
306d  
306n  
306p  
A
B
306n  
306f  
306k  
306b  
306j  
306u  
TI4564a  
306c  
309909H  
51  
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Parts  
User Interface  
234620, for pump-based and pump/meter units  
234621, for meter-based units only  
Ref.  
Ref.  
No. Part No. Description  
Qty.  
No. Part No. Description  
Qty.  
1
1
410 245706 CIRCUIT BOARD, display;  
includes jam nut (N)  
411 112546 SCREW, machine;  
4-40 x 3/8 in. (10 mm)  
412 15A856 PANEL, display  
413 C27076 NUT, lock, w/nylon insert; 4-40  
414 111907 MOUNT, tie wrap  
416 15A854 HARNESS, wire, display  
418 188438 WASHER; 0.120 in.  
419 101366 SCREW, set; socket hd;  
10-24 x 5/16 (8 mm)  
401 15B062 DISPLAY  
403 15A851 HARNESS, wire  
404 15A801 GASKET; neoprene  
405 15D853 KNOB, control  
406 15A850 HARNESS, wire  
407 15A852 HARNESS, wire, switch  
408 15D796 LABEL, control, upper; 234620  
only  
15D797 LABEL, control, upper; 234621  
only  
409 15D798 LABEL, control, lower; 234620  
only  
1
1
1
1
1
1
2
1
4
3
1
4
1
1
1
1
15D799 LABEL, control, lower; 234621  
only  
404  
408  
413 418  
410  
411  
N
407  
406  
405  
407  
419  
403  
416  
403  
409  
401  
406  
416  
TI4755a  
TI4756a  
52  
309909H  
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Parts  
287230 Pump Air Control  
287231 Meter Air Control  
Ref.  
Ref.  
No. Part No. Description  
Qty.  
No. Part No. Description  
Qty.  
2
1
207 113498 VALVE, safety relief;  
110 psi (0.8 MPa, 8 bar)  
208 119246 STANDOFF  
209 100081 BUSHING, pipe; 1/2 npt(m) x  
3/8 npt(f)  
201 15D814 MANIFOLD, air; 287230 only  
15D814 MANIFOLD, air; 287231 only  
202 206197 REGULATOR, air; 1/2 npt(f) inlet  
and outlet; 287230 only;  
1
1
4
1
see manual 308168  
1
1
2
210 C19024 ELBOW, swivel; 1/2 npt(m) x  
1/2 npsm(f)  
203 119240 CAP, pipe, 1/2 in. (13 mm)  
204 101689 GAUGE, air pressure; 287230  
only  
1
101689 GAUGE, air pressure; 287231  
only  
3
1
205 112678 PLUG; 1/4 npt; 287230 only  
206 118762 VALVE, ball, bleed-type;  
1/2 npt(fbe)  
* These parts are included in 287230 Air Control only.  
203  
205*  
201*  
*204  
202*  
205*  
*205  
208  
207  
204  
201  
209  
210  
208  
TI4601a  
206  
309909H  
53  
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Technical Data  
Technical Data  
Mix ratio range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1:1-10:1 (in 0.1 increments), pump-based systems  
0.1:1-30:1 (in 0.1 increments), meter-based systems  
Ratio tolerance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . up to +/- 1%  
Flow rates  
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 qt/min (0.02 lpm)*, pump-based systems  
0.1 qt/min (0.1 lpm)*, meter-based systems  
Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 gpm (3.8 lpm)  
Pump size  
UltraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 cc/cycle  
HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 cc/cycle  
Pump cycle length  
(one cycle = one upstroke and one downstroke)  
UltraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 in. (152 mm)/cycle  
HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 in. (193 mm)/cycle  
Fluid viscosity range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20,000 cps (heavier viscosities can be mixed with use  
of optional heaters, heated hoses, and hardware)  
Fluid filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mesh (238 micron) standard  
Maximum fluid working pressure  
2.5:1 UltraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 psi (1.7 MPa, 17 bar)  
24:1 HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400 psi (16 MPa, 166 bar)  
34:1 HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . 3400 psi (23 MPa, 234 bar)  
47:1 HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . 4700 psi (32 MPa, 324 bar)  
Meter-based systems . . . . . . . . . . . . . . . . . . . . . 4000 psi (28 MPa, 280 bar)  
Air supply pressure range. . . . . . . . . . . . . . . . . . . . . . . . . 60-110 psi (420-800 kPa, 4.2-8 bar)  
Maximum air consumption at 100 psi (0.7 MPa, 7 bar)  
3
2.5:1 UltraMix . . . . . . . . . . . . . . . . . . . . . . . . . . .  
24:1 HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . .  
34:1 HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . .  
47:1 HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . .  
10.8 scfm at 1 gpm (0.30 m /min at 3.8 lpm)  
3
40.5 scfm at 1 gpm (1.13 m /min at 3.8 lpm)  
3
54.7 scfm at 1 gpm (1.53 m /min at 3.8 lpm)  
3
63.0 scfm at 1 gpm (1.76 m /min at 3.8 lpm)  
Ambient temperature range  
Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-104° F (0-40° C)  
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160° F (–1-71° C)  
*
Minimum flow rate is dependent on the material being sprayed and mixing capability. Test your material for spe-  
cific flow rate.  
54  
309909H  
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Technical Data  
External Power Supply Requirements . . . . . . . . . . . . . . . 93-250 Vac, 50/60 Hz, 1.2 amps maximum draw  
15 amp maximum circuit breaker required  
14 AWG power supply wire gauge  
Environmental Conditions Rating . . . . . . . . . . . . . . . . . . . Indoor/outdoor  
Altitude up to 4000 meters  
Maximum relative humidity to 99% up to 40° C  
Pollution degree (1)  
Installation category (2)  
Sound pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 dBA at 100 psi (0.7 MPa, 7 bar)  
Fluid inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
UltraMix Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . See 310671  
HydraMix Pumps . . . . . . . . . . . . . . . . . . . . . . . . . See 310672  
Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 308778  
Fluid outlet size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
UltraMix Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . See 310671  
HydraMix Pumps . . . . . . . . . . . . . . . . . . . . . . . . . See 310672  
Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 308778  
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
UltraMix Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . See 310671  
HydraMix Pumps . . . . . . . . . . . . . . . . . . . . . . . . . See 310672  
Wetted parts  
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 310662  
Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . . . See 310655  
Mix Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 310654  
Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 308778  
PC Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-232  
309909H  
55  
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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  
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 309909  
Graco Headquarters: Minneapolis  
International Offices: Belgium, China, Japan, Korea  
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441  
Copyright 2005, Graco Inc. is registered to ISO 9001  
Revised 02/2010  
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