Graco PrecisionFlo XL User manual

Instructions–Parts List
309375F
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
PrecisionFlo™XL Metering
Modules
5000 psi (345 bar, 34.5 MPa) Maximum Inlet Pressure
3500 psi (240 bar, 24 MPa) Maximum Fluid Working Pressure
120 psi (8.3 bar, 0.83 MPa) Maximum Air Working Pressure
For use when dispensing fluids that meet at least one of the following conditions for non-flammability:
DThe fluid has a flash point above 140_F (60_C) and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93.
DThe fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test.
TI1418C

2 309375
Table of Contents
Instruction Manual Conventions 2. . . . . . . . . . . . . . .
List of Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Metering Assembly Overview 6. . . . . . . . . . . . .
Pneumatic Fluid Metering Assembly 7. . . . . . . . . . .
PrecisionFlo XL Pneumatic Fluid Regulator 7. . . . .
Typical Fluid Applications 7. . . . . . . . . . . . . . . . . . . .
Electric Fluid Metering Assembly 7. . . . . . . . . . . . . .
PrecisionFlo Metering Valve 7. . . . . . . . . . . . . . . . . .
PrecisionFlo XL Module Overview 8. . . . . . . . . . . . . .
Installing Fluid Metering Assembly 9. . . . . . . . . . . . .
Installing the Fluid Metering Assembly 11. . . . . . . .
Grounding the Fluid Metering Assembly 11. . . . . . .
Connecting Fluid Lines and Cables 11. . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 13. . . . . . . . . . . . . . . . . .
Prepare the System for Service 14. . . . . . . . . . . . . .
Servicing the Flow Meter 14. . . . . . . . . . . . . . . . . . . .
Parts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PrecisionFlo XL Modules 18. . . . . . . . . . . . . . . . . . .
Technical Data 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 34. . . . . . . . . . . . . . . . . . . . .
Graco Information 34. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manual
Conventions
The following table contains the abbreviations that are
used in this manual:
Abbreviation: Stands For:
PVC Poly Vinyl Chloride
psi pounds per square inch
V volts
Vac volts ac
Vdc volts dc
Reference numbers (10) and letters (A) in parentheses
in this manual’s text refer to the numbers and letters in
the illustrations.
List of Models
Table 1 — PrecisionFlo Module – Model Numbers
PrecisionFlo XL
Module No. Description
198245
High viscosity precision pneumatic regulator with helical gear flow meter
198245 Hi
g
h viscosit
y
p
recision
p
neumatic re
g
ulator with helical
g
ear flow meter
198245
High
viscosity
precision
pneumatic
regulator
with
helical
gear
flow
meter
gypp g g
198246
Low viscosity precision pneumatic regulator with helical gear flow meter
198246
L
ow v
i
scos
it
y prec
i
s
i
on pneuma
ti
c regu
l
a
t
or w
ith
h
e
li
ca
l
gear
fl
ow me
t
er
198247
Low viscosity precision pneumatic regulator with spur gear flow meter
198247 Low viscosit
y
p
recision
p
neumatic re
g
ulator with s
p
ur
g
ear flow meter
198247
Low
viscosity
precision
pneumatic
regulator
with
spur
gear
flow
meter
yp p g p g
198184
198184
Low viscosity precision pneumatic regulator without flow meter
198185
L
ow v
i
scos
i
ty prec
i
s
i
on pneumat
i
c regu
l
ator w
i
t
h
out
fl
ow meter
198187
High viscosity precision pneumatic regulator without flow meter
198188
Hi
g
h
v
i
scos
i
ty prec
i
s
i
on pneumat
i
c regu
l
ator w
i
t
h
out
fl
ow meter
233652 Low viscosity precision electric regulator without a flow meter
233653 Low viscosity precision electric regulator with spur gear flow meter
233654 Low viscosity precision electric regulator with helical gear flow meter
233672 High viscosity precision electric regulator without a flow meter
233673 High viscosity precision electric regulator with helical gear flow meter
245315 High viscosity precision electric regulator with helical gear flow meter and an
integrated pneumatic mastic regulator
245316 High viscosity precision electric regulator with an integrated pneumatic mastic
regulator, without flow meter

309375 3
Warnings
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
SKIN INJECTION HAZARD
Spray from the dispensing device, hose leaks, or ruptured components can inject fluid into your body
and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on
the skin can also cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi-
cal attention.
DDo not point the dispensing device at anyone or at any part of the body.
DDo not put hand or fingers over the front of the dispensing device.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DFollow the Pressure Relief Procedure on page 13 whenever you are instructed to: relieve pres-
sure; stop dispensing; clean, check, or service the equipment; or install or clean a spray tip or
nozzle.
DTighten all the fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
DALWAYS wear eye protection and protective clothing when installing, operating, or servicing this
dispensing equipment.
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled.
DKnow the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
Follow the fluid manufacturer’s recommendations.
DProvide fresh air ventilation to avoid the buildup of vapors from the fluid being dispensed.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DWear the appropriate protective clothing, gloves, eyewear, and respirator.

4 309375
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, warnings, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call your
Graco distributor.
DOnly use the PrecisionFlo metering valve with the PrecisionFlo Control Assembly.
DOnly use a dispensing device appropriate for the fluid and application method, and capable of
operating at the highest possible fluid supply pressure the module may experience.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck the equipment daily. Repair or replace worn or damaged parts immediately.
DDo not disassemble the PrecisionFlo metering valve motor. The motor contains powerful mag-
nets, which could attract metal objects and create a hazardous condition if the motor end plates
are removed. Contact your Graco distributor for motor service.
DDo not exceed the maximum working pressure of the lowest rated system component. The
maximum working pressure of the PrecisionFlo metering valve is shown on the fluid head.
Other components may have lower working pressure ratings.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180_F (82_C) or below –40_F (–40_C).
DDo not use the hoses to pull the equipment.
DUse only fluids that are compatible with the equipment wetted parts. See the Technical Data
sections of all the equipment manuals. Read the fluid manufacturer’s warnings.
DComply with all applicable local, state and national fire, electrical and other safety regulations.
DDo not touch the metal heat sink on the metering valve when the surface is hot.
DDo not cover the PrecisionFlo metering valve; the motor needs air ventilation for cooling.
DDo not attempt to modify the programming of the module. Any modification of the programming
could result in serious injury or damage to the module.
MOVING PARTS HAZARD
Moving parts, such as the fluid needle, can pinch fingers.
DDo not operate the equipment with the guard removed.
DKeep clear of any moving parts when starting or operating the equipment.

309375 5
WARNING
FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in fire or explosion and serious injury.
DGround the equipment and the object being sprayed. The PrecisionFlo metering valve is grounded
through proper connection of the two electrical cables. See Ground the Fluid Metering Assem-
bly on page 11.
DIf there is any static sparking or you feel an electric shock while using the equipment, stop dis-
pensing immediately. Do not use the equipment until you have identified and corrected the
problem.
DMake sure all electrical work is performed by a qualified electrician only.
DHave any checks, installation, or service to electrical equipment performed by a qualified electrician
only.
DMake sure all electrical equipment is installed and operated in compliance with applicable codes.
DDo not install the PrecisionFlo module in a hazardous area, as defined in Article 500 of the National
Electrical Code (USA).
DMake sure power is disconnected when servicing and repairing equipment.
DKeep the dispensing area free of debris, including solvent, rags, and gasoline.
DBefore operating the equipment, extinguish all open flames or pilot lights in the dispense area.
DDo not smoke in the dispensing area.
DDisconnect the two electrical cables from the PrecisionFlo metering valve before servicing the
valve.
DKeep liquids away from the electrical components
DTurn off power to the PrecisionFlo module before disconnecting any cables connected to the con-
trol assembly or fluid metering assembly.
DDisconnect electrical power at the main switch before servicing the equipment.

6 309375
Fluid Metering Assembly Overview
Pneumatic Fluid Metering Assembly
The fluid metering assembly (Fig. 1) can be attached
to a robot arm, or mounted on a pedestal. Main com-
ponents of the fluid metering assembly are:
DPrecisionFlo XL pneumatic fluid regulator (A)
Dflow meter (B) to precisely measure the amount of
fluid dispensed (optional)
Dsolenoid air valve (C) that controls a dispense
device
Dvoltage to pressure (v/p) controller (D) for adjusting
the air pressure to the fluid regulator (A)
Fig. 1
B
C
A
DTI1417C
PrecisionFlo XL Pneumatic Fluid
Regulator
The PrecisionFlo XL pneumatic fluid regulator is a pre-
cision fluid pressure regulator that uses air pressure to
control fluid pressure and to provide fast response to
electronic commands and ensure a precisely con-
trolled, continuous flow of material.
The PrecisionFlo XL module combines continuous
pressure control with the ability to change bead profiles
almost instantaneously. When used with one of the
optional flow meters, the PrecisionFlo XL module
automatically adjusts for fluctuations in the operating
environment, such as material viscosity, temperature,
and robot speed, while maintaining the desired dis-
pense rate.
The PrecisionFlo XL metering valve is electrically
controlled by the PrecisionFlo XL module and consis-
tent material flow is assured by a closed-loop pressure
control design which also adjusts for flow rate. The
module responds to robot-supplied signals to provide
an accurate and consistent output flow based on a
comparison of actual to desired flow rates.
Typical Fluid Applications
DPVC Sealer
DPlastisols
DSound deadening materials
DBody panel reinforcement

309375 7
Fluid Metering Assembly Overview
Electric Fluid Metering Assembly
The fluid metering assembly (Fig. 2) can be attached
to a robot arm, or mounted on a pedestal. Main com-
ponents of the fluid metering assembly are:
DPrecisionFlo metering valve (A )
Dflow meter (B) to precisely measure the amount of
fluid dispensed and close the flow control loop
Dsolenoid air valve (C) that controls a dispense
device
Dmetering valve closer (D)
Dsolenoid air valve (E) that controls the metering
valve’s closer
Fig. 2
D
B
A
C
E
TI1554A
PrecisionFlo Metering Valve
The PrecisionFlo metering valve (Fig. 3) is a precision
fluid pressure regulator that uses a magnetic linear
servo motor to regulate material pressure and flow.
The needle assembly is directly connected to the linear
servo motor, so the needle responds immediately to
any motor movement.
TI1394A
Fig. 3
PrecisionFlo XL
Metering Valve

8 309375
PrecisionFlo XL Module Overview
The block diagram in Fig. 4 shows an example of the
PrecisionFlo XL module.
The fluid metering assembly contains the components
that control and monitor fluid dispensing. It can be
attached to a robot arm or mounted on a pedestal.
The control assembly sends continuous voltage sig-
nals to the PrecisionFlo metering valve to control
opening and closing of the metering valve.
The control assembly receives input from the robot
controller, user-programmed values, and components
on the fluid metering assembly. The control assembly
uses this input to determine the signal it should send to
the controller.
The PrecisionFlo XL metering valves are electrically
controlled by the PrecisionFlo XL module, and consis-
tent material flow is assured by a closed–loop pressure
or closed–loop flow control design. The module re-
sponds to robot–supplied signals to provide an accu-
rate and consistent output flow based on a comparison
of actual to desired flow rates. The electric regulator
has a needle directly connected to the motor shaft,
yielding nearly instantaneous adjustments to the
material flow rate, while the pneumatic regulator uses
air pressure to control fluid pressure and to provide
fast response to electronic commands and ensure a
precisely controlled, continuous flow of material.
Dispense
Measure Volume
Style Bits 1, 2, 4, 8, 16
Volume Request
Fault Acknowledge
Fault Strobe
Dispenser Ready
Data Bus 16 bit
Volume Valid
Robot Controller
Flow Command
Gun On
Temperature Fault (from optional conditioning system)
Flow Meter
Outlet Pressure
Inlet Pressure
Fig. 4
PrecisionFlo XL
Control Assembly
PrecisionFlo XL
Control Assembly
PrecisionFlo XL
Fluid Metering Assembly
V/P Closer Signal

309375 9
Installing Fluid Metering Assembly
To install the fluid metering assembly hardware:
DInstall the PrecisionFlo fluid metering assembly
DGround the PrecisionFlo system
DConnect the PrecisionFlo fluid metering assembly
to the control assembly
DConnect fluid lines and cables
Installing the Fluid Metering Assembly
WARNING
ELECTROCUTION HAZARD
Installing and servicing this equipment
requires access to parts which could
cause an electric shock or other serious
injury. Have only qualified electricians access the
fluid metering assembly .
Preparing to Install the Assembly
Before installing the fluid metering assembly:
DSee component manuals for specific data on com-
ponent requirements. Data presented here pertains
to the PrecisionFlo fluid metering assembly only.
DHave all system and subassembly documentation
available during installation.
DBe sure all accessories are adequately sized and
pressure-rated to meet the system’s requirements.
DUse only the Graco PrecisionFlo fluid metering
assembly with the PrecisionFlo control assembly.
Installing the Assembly
WARNING
EQUIPMENT MISUSE HAZARD
The fluid metering assembly weighs
approximately 60 lbs and should never
be moved or lifted by one person. Use
adequate personnel and support devices when
mounting, moving or handling the control assembly
to prevent equipment damage or personal injury.
1. Select a location for the PrecisionFlo fluid metering
assembly. Keep the following in mind:
DAllow sufficient space for installing and using
the equipment.
DMake sure all fluid lines, cables and hoses
easily reach the components they will be
connected to.
DMake sure the fluid metering assembly allows
the robot to move freely along all axes.
DMake sure the fluid metering assembly pro-
vides easy access for servicing its compo-
nents.
2. Locate and secure the PrecisionFlo XL fluid meter-
ing assembly to the robot (or other mounting
surface) with four 3/8 in. bolts through the 0.42 in.
diameter holes in the base plate. See the mounting
dimensions for the electric regulator system in Fig.
5.
Measurements, inches (mm)
A17.0 (432)
B16.0 (407)
C15.0 (381)
D14.0 (356)
Fig. 5
0.42 in. diameter
holes (typical)
A
B
C
D
Models 233652, 233653, 233654, 233672, 233673

10 309375
Installing Fluid Metering Assembly
3. See the mounting dimensions for the pressure/flow
regulating system in Fig. 6 and for the remote–
mount flow meter in Figs. 7 and 8.
Measurements, inches (mm)
Fig. 6 Fig. 7 Fig. 8
A17.0 (432) 20.0 (503) 20.0 (503)
B16.0 (407) 19.0 (483) 19.0 (483)
C15.0 (381) 8.0 (204) 8.0 (204)
D14.0 (356) 7.0 (178) 7.0 (178)
Air to
Dispense
Valve
Fig. 6
A
B
C
D
Pressure/flow regulating system
Air Inlet
1/4 npt (F)
Models 198245, 198246, 198247
Close
Open
4 mm
or 5/32”
tubing
TI1418d
Fig. 7
A
B
C
D
Pressure regulation only, remote-mount flow meter
Models 198184, 198185, 198187, 198188
TI
1
Fig. 8
A
B
C
Remote-mount flow meter
D
TI1553A
4. See the mounting dimensions for models with a
subplate and fluid inlet pressure regulator in Fig. 9.
Measurements, inches (mm)
A24.0 (609)
B23.0 (584)
C19.0 (483)
D18.0 (457)
Fig. 9
AB
C
D
Subplate and fluid inlet pressure regulator
Models 245315, 245316
TI1596A

309375 11
Installing Fluid Metering Assembly
Grounding the Fluid Metering Assembly
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock:
DThe PrecisionFlo fluid metering assem-
bly must be electrically connected to a
true earth ground; the ground in the
electrical system may not be sufficient.
DAll wires used for grounding must be
8 AWG (8.36 mm2) minimum.
DA qualified electrician must complete all ground-
ing and wiring connections.
DRefer to your local code for the requirements for
a “true earth ground” in your area.
DAlso read and follow the warnings on pages 3
through 5.
CAUTION
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty will be voided.
Ground the fluid metering assembly as instructed here
and in the individual component manuals. Make sure
the fluid metering assembly and its components are
installed correctly to ensure proper grounding.
Control Assembly
Ground the control assembly as instructed in manual
309374.
Air and Fluid Hoses
For static dissipation, use only electrically conductive
hoses or ground the valves.
Metering Module
The PrecisionFlo XL metering valve is grounded to the
control assembly through proper connection of the
electrical cable provided with the metering module.
Remote Flow Meter Installation
See PrecisionFlo XL instruction manual 309374.
Dispense Device
Follow the grounding instructions in the dispense
device documentation.
Connecting Fluid Lines and Cables
After a fluid metering assembly is connected to a
control assembly, the units are called a PrecisionFlo
module.
1. Install the fluid metering assembly on the robot or
in another appropriate place, as instructed on
page 9. Ground the system as instructed on page
11.
2. Air must be clean and dry, between 60–120 psi.
Flush air line before plumbing in air filter assembly
(234967). Plumb in air filter assembly near air drop
site (upstream of fluid plate module). Adding an air
regulator to this line will provide more consistent
dispense valve response times. Connect the air
lines to the ports on the fluid metering assembly as
shown in Fig. 6.
3. Make the fluid line connections for the fluid meter-
ing assembly according to the connection size
chart in the Technical Data section of this manual
(page 32).
4. Connect the OP cable from the control box to the
fluid plate junction box on all models. Connect the
motor cable on models with the electric regulator.
WARNING
When the second outlet port on the 198245,
198187, and 198188. Fluid plate is not used, it
must be plugged with the supplied steel plug to
prevent high pressure fluid from being emitted from
the port. High pressure fluid can cause serious
injury.

12 309375
Troubleshooting
Refer to control manual, 309374, which contains the
valid fault codes, possible causes, and solutions for
the PrecisionFlo XL module, which includes the fluid
metering assembly. Also refer to the section on
Troubleshooting and Fault Recovery for detailed
information on how fault codes are communicated.
Troubleshooting for individual regulators and flow
meters is discussed in their separate manuals. These
manuals are called out in the parts lists later in this
manual.

309375 13
Service
Pressure Relief Procedure
This procedure describes how to relieve pressure
between the PrecisionFlo metering valve assembly
and the automatic dispense valve. See your supply
unit or system documentation for instructions on
relieving pressure for the entire dispensing system.
Use this procedure whenever you shut off the dispense
valve and before checking or adjusting any part of the
system, to reduce the risk of serious injury.
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected
through the skin and cause serious
injury. To reduce the risk of an injury
from injection, splashing fluid, or moving
parts, follow the Pressure Relief
Procedure whenever you:
Dare instructed to relieve the pressure
Dstop spraying/dispensing
Dinstall or clean the nozzle
Dcheck or service any of the system
equipment.
PRESSURIZED FLUID HAZARD
High pressures can cause serious injury.
Be sure to open the dispense valve
during system heat-up to alleviate
pressure which might occur in the sys-
tem due to material expansion.
WARNING
INJECTION HAZARD
The PrecisionFlo XL module pressure
must be manually relieved to prevent the
module from starting or spraying
accidentally. To reduce the risk of an
injury including fluid injection, splashing
in the eyes or on the skin, or injury from
moving parts, always follow the
Pressure Relief Procedure whenever
you:
Dare instructed to relieve the pressure
Dcheck or service any of the system
equipment
Dshut off the pump or install or clean
the spray tip.
1. Shut off the fluid supply to the metering valve.
2. Shut off power and air to the fluid supply systems
3. Place a waste container beneath the fluid drain
valve, which is located at the filter. Place a waste
container beneath the dispense device.
4. Slowly open the drain valves located at each filter,
to relieve pressure.
5. Leave the drain valves open until you are ready to
pressurize the system again.
6. In Manual Dispense Mode, touch and hold the
Dispense Gun button. This will actuate the meter-
ing valve and the dispensing device and relieve
fluid pressure.
7. Refer to Fig. 10 and perform the following steps to
open the dispense device and relieve fluid pres-
sure:
a. To relieve fluid pressure, manually actuate the
plunger on the solenoid (C) that opens the
dispense device.
b. Continue actuating the plunger until all pres-
sure is purged from the system between the
needle and the dispense device before pro-
ceeding.
Fig. 10
To dispense
valve C
NOTE: If, after following the steps above, you suspect
that a valve, hose, or the mixer dispenser nozzle has
become completely clogged, or that pressure has not
been fully relieved, VERY SLOWLY loosen the mixer
shroud or hose end coupling and gradually relieve the
pressure. Then loosen completely and clear the tip,
valve, or hose. DO NOT attempt to pressurize the
system until the blockage is cleared.

14 309375
Service
This section describes how to remove and replace
these components on the fluid metering assembly:
Dflow meter (20) (Fig. 11)
Dmetering valve (14) (Fig. 13)
NOTE: The numbers in parentheses in the text refer to
reference numbers in the parts drawings and parts
lists.
Prepare the System for Service
1. Shut off the material supply.
2. Shut off the system air.
3. Relieve the system pressure.
WARNING
To reduce the risk of serious injury, whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 13.
Servicing the Flow Meter
There are no serviceable parts in the flow meter (20).
To correct a problem with the flow meter, refer to the
maintenance and troubleshooting sections of the Flow
Meter Manual, 308968.
Remove the Flow Meter from the Mounting Plate
1. Prepare the system for service as instructed
above.
2. Disconnect the flow meter cable (J) from the flow
meter sensor. See Fig. 11.
3. Disconnect the material hose (K).
4. Disconnect the swivel fitting (18) from the
regulator.
5. Loosen the two screws (12), and remove the
curved bracket (22).
6. The flow meter (20) weighs approximately 15 lbs.
(6.75 kg). Carefully lift it off the mounting plate
(10).
Fig. 11
K
22
20 12
10
J
18 TI1417d

309375 15
Service
Install the Flow Meter on the Mounting Plate
1. Rest the flow meter (20) on the flow meter bracket
(23) while threading the swivel fitting (18) onto the
metering valve material inlet. See Fig. 11 and 12.
2. Tighten the swivel fitting (18) to the metering valve
material inlet.
3. Place the curved bracket (22) over the flow meter,
then tighten the two screws (12) to hold the brack-
et and flow meter in place.
4. Check that the flow meter (20) and regulator (14)
are still aligned.
5. Connect the material hose (K).
6. Connect the flow meter cable (J).
Fig. 12
22
12
23
20
Servicing the Metering Valve
Remove the metering valve (14) from the mounting
plate (10) and replace it with a new unit. For informa-
tion about servicing the metering valve or the metering
valve’s sensor, see the metering valve manual,
309382.
Remove the Metering Valve from the Mounting
Plate
1. Prepare the system for service as instructed on
page 13.
2. Disconnect the motor power cable from the meter-
ing valve connector (L). See Fig. 13.
3. Disconnect the pressure sensor cables from the
junction box connectors (N).
4. Disconnect the closer air line from the closer air
inlet (M).
5. Disconnect the material line from the metering
valve material outlet (O).
6. Disconnect the swivel fitting (18) from the metering
valve.
7. Remove the screws (16), from the rear metering
valve bracket (15).
8. Remove the screws (16), from the front metering
valve bracket (11).
9. The metering valve (14) weighs approximately 18
lbs. (8.16 kg). Carefully lift it off the mounting plate
(10).
11, 16
15, 16
Fig. 13
M
K
20
18
O
10
14
L
N

16 309375
Service
Servicing the Metering Valve (con’t)
Install the Metering Valve on the Mounting Plate
1. Place the metering valve (14) on the mounting
plate (10). Secure it with the rear and front meter-
ing valve brackets (15 and 11), screws (16). See
Fig. 14.
2. Check that the flow meter (20) and metering valve
(14) are aligned.
3. Tighten the swivel fitting (18) onto the metering
valve material inlet. See Fig. 14.
4. Connect the material line to the metering valve
material outlet (O).
5. Connect the motor power cable to the metering
valve connector (L).
6. Connect the pressure sensor cables to the junction
box connectors (N).
7. Connect the closer air line to the closer air inlet
(M).
Fig. 14
8
22
L
15,16
14
11, 16
O
18
10
M
N
20

309375 17
Service
NOTE: For complete fluid regulator service refer to
instruction manual 308647. For Mastic Fluid Regula-
tors (part no. 244740) refer to instruction manual
307517.
Replacing the Cartridge
See Fig. 15 and perform the following steps.
CAUTION
Handle the hard carbide parts ball , valve actuator ,
and valve seat , carefully to avoid damaging them.
1. Relieve the pressure.
WARNING
To reduce the risk of serious injury, whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 13.
2. Remove the cartridge assembly by loosening the
valve housing (5) with a 6mm hex wrench and
pulling the cartridge assembly out of the base
housing (4).
NOTE: The retaining nut (3) often loosens when
removing the cartridge assembly from the base
housing. Be sure to re–torque as described in step
4.
3. Inspect and clean the internal walls of the base
housing (4).
NOTE: Be careful that you do not scrape or gouge
the internal walls of the base housing. They are a
sealing surface.
4. Re-torque the retaining nut (3) to 140 to 160 in-lb
(16 to 18 N-m).
NOTE: You must re-torque the retaining nut be-
fore you install it in the base housing in step 5.
5. Install the new cartridge assembly in the base
housing (4), and torque the valve housing (5) to 30
to 35 ft-lb (41 to 48 N-m).
NOTE: The valve seat is double sided and may be
reversed for extended life. The o-ring and ball
must be replaced. See instruction manual 308647
Service Kits for Regulator 244734
For the Fluid Diaphragm Repair Kit, order Part No.
238747.
For the Cartridge Repair Kit, order Part No. 238748.
To convert from a spring-operated to an air-operated
regulator, order the Air-Operated Conversion Kit, Part
No. 238749.
Fig. 15 06656
3
1
Torque Sequence for Regulator
Base Housing Screws (9)
4
2
5
4
cartridge
assembly
diaphragm
and valve
actuator
subassembly
3

18 309375
Parts
PrecisionFlo XL Modules (Part Nos. 198184 and 198185)
TI1421B
11 20 8
18
14 1
10
3
12
24
23
21
22
16
26
13
4
25 19
7
29
Ref.
No. Part No. Description Qty.
1 107530 SCREW, cap, sch, hex 6
3 552069 LABEL, metalized 1
4 054753 TUBE, nylon, rd, black 1.6
7 112671 SCREW, cap, sch 2
8 115713 BRACKET, tube 1
9 234967 MUFFLER, inline filter (not
shown) 1
10 195942 REGULATOR, I/P 1
11 197829 PLATE, fluid, SD 1
12 198082 SENSOR, pressure 2
13 198171 FITTING, elbow 1
14 198175 FITTING, push 1
Ref.
No. Part No. Description Qty.
16 198177 FITTING, push, straight 2
18 198179 FITTING, bulkhead, union 1
19 198182 SCREW, cap, sch 2
20 198183 BOX, junction 1
21 198226 SCREW, cap, sch 1
22 198231 BRACKET, regulator 1
23 244734 REGULATOR, assembly, XL
(see manual 308647) 1
24 551348 VALVE, sol. 4-way 24 Vdc
1/8 npt 1
25 C06061 MUFFLER, sintered, dia 1/8 2
26 C19800 SCREW, cap, sch 2
29 196108 PLUG, din 1

309375 19
Parts
PrecisionFlo XL Fluid Plate, High Flow (Part No. 198187 and 198188)
23
21
15
24 3
9
17
6
22
19
25
16
26
4
5
1
11
13
10 14 TI1422B
Ref.
No. Part No. Description Qty.
1 107530 SCREW, cap, sch 8
3 552069 LABEL, metalized 1
4 198268 BOLT, U 1
5 198269 BRACKET, regulator 1
6 054753 TUBE, nylon, rd, black 1.6
9 108328 SCREW, cap, sch 2
10 112671 SCREW, cap, sch 2
11 115713 BRACKET, tube 1
12 234967 MUFFLER, inline filter (not
shown) 1
13 195942 REGULATOR, I/P 1
14 197829 PLATE, fluid, SD 1
15 198082 SENSOR, pressure 2
Ref.
No. Part No. Description Qty.
16 198171 FITTING, elbow 1
17 198175 FITTING, push 1
19 198177 FITTING, push, straight 2
21 198179 FITTING, bulkhead, union 1
22 198182 SCREW, cap, sch 2
23 198183 BOX, junction 1
24 244740 REGULATOR, mastic, 500
psi (see manual 307517) 1
25 551348 VALVE, sol. 4-way 24 Vdc
1/8 npt 1
26 C06061 MUFFLER, sintered, dia 1/8 2

20 309375
Parts
PrecisionFlo XL Fluid Plate, Low Flow, RS (Part No. 198246)
13 26
3
5
21
14
12
6
18
20
23
10
9
6
30
29
16
19
24 22 25 2
27
1
32
28
31
TI1417B
Ref.
No. Part No. Description Qty.
1 107530 SCREW, cap, sch 8
2 110580 SCREW, cap, sch 2
3 157191 FITTING, adapter 1
5 552069 LABEL, metalized 1
6 054753 TUBE, nylon, rd, black 2.4
9 112671 SCREW, cap, sch 2
10 115713 BRACKET, tube 1
11 234967 MUFFLER, inline filter (not
shown) 1
12 195942 REGULATOR, I/P 1
13 198082 SENSOR, pressure 2
14 198175 FITTING. push 1
16 198177 FITTING, push, straight 3
Ref.
No. Part No. Description Qty.
18 198179 FITTING, bulkhead, union 1
19 198182 SCREW, cap, sch 2
20 198183 BOX, junction 1
21 198186 PLATE, fluid, RS 1
22 198226 SCREW, cap, sch 1
23 198230 FITTING, swivel 1
24 198231 BRACKET, regulator 1
25 198242 BRACKET, flow meter 1
26 617418 METER, flow
(see manual 308968) 1
27 198244 BRACKET, mounting 1
28 244734 REGULATOR, assembly, XL
(see manual 308647) 1
29 551348 VALVE, sol. 4-way 24 Vdc
1/8 npt 1
30 C06061 MUFFLER, sintered, dia 1/8 2
31 C19800 SCREW, cap, socket head 2
32 198579 HARNESS, cable, with con-
nector SRZ 40 2