Graco XM Series Use and care manual

Repair-Parts
XM Plural-Component
Sprayers
For spraying two-component epoxy and urethane protective coatings in hazardous and
non-hazardous locations. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.
313289V
EN
See pages 10 and 11 for Models information and
Approvals.
See Technical Data on page 76 for maximum
working pressure.

2313289V
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Isocyanate (ISO) Information . . . . . . . . . . . . . . 8
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 8
Material Self-Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Keep Components A and B Separate . . . . . . . . . . . . . . 8
Moisture Sensitivity of Isocyanates . . . . . . . . . . . . . . . . 9
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Before Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Proper Lifting of Sprayer . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 13
Flush Before Using Equipment . . . . . . . . . . . . . . . . . . 14
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Flush Mixed Material . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Empty and Flush Entire System
(new sprayer or end of job) . . . . . . . . . . . . . . . . . 16
Shutdown Entire System . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replace Air Filter Element . . . . . . . . . . . . . . . . . . . . . 21
User Interface/Control Box . . . . . . . . . . . . . . . . . . . . . 22
Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fluid Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . 32
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fluid Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Simplified Electrical Schematic,
XM Sprayer with Alternator . . . . . . . . . . . . . . . . . 37
Simplified Pneumatic Schematic,
XM Sprayer with Alternator . . . . . . . . . . . . . . . . . 38
Detailed Electrical Schematic,
XM Sprayer with Alternator (page 1) . . . . . . . . . . 39
Detailed Electrical Schematic,
XM Sprayer with Alternator (page 2) . . . . . . . . . . 40
Simplified Electrical Schematic,
XM Sprayer with Wall Power . . . . . . . . . . . . . . . . 41
Simplified Pneumatic Schematic,
XM Sprayer with Wall Power . . . . . . . . . . . . . . . . 42
Detailed Electrical Schematic,
XM Sprayer with Wall Power (page 1) . . . . . . . . 43
Detailed Electrical Schematic,
XM Sprayer with Wall Power (page 2) . . . . . . . . 44
Junction Box Wiring Schematics . . . . . . . . . . . . . . . . . . 45
Fluid Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hopper Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Control Box (255771) Parts . . . . . . . . . . . . . . . . . . . . 60
Junction Box (256540) Parts . . . . . . . . . . . . . . . . . . . 65
Fluid Control Assembly Parts . . . . . . . . . . . . . . . . . . . 66
Air Inlet Manifold (255762) Parts . . . . . . . . . . . . . . . . 67
Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . 78

Related Manuals
313289V 3
Related Manuals
Manuals are available at www.graco.com.
Component Manuals in U.S. English:
Manual Description
312359 XM Plural-Component Sprayers
Operation
313292 XM Plural-Component OEM Sprayers
Instructions-Parts
311762 Xtreme®Displacement Pumps
Instructions-Parts
3A5423 XL6500 and XL3400 Air Motor
Instructions-Parts
312747 Double Wall Hopper Kit
Instructions-Parts
309524 Viscon®HP Heater Instructions-Parts
312145 XTR™5 and XTR™7 Spray Guns
Instructions-Parts
312769 Feed Pump and Agitator Kits
Instructions-Parts
312794 Merkur®Pump Assembly
Instructions-Parts
406699 7-Gallon Hopper Installation Kit
Instructions-Parts
406739 Desiccant Kit Instructions-Parts
406690 Caster Kit Instructions-Parts
406691 Hose Rack Kit Instructions-Parts
313258 Electric Heated Hose Power Supply
Kit Instructions-Parts
313259 Hopper or Hose Heat Circulation Kit
Instructions-Parts
312770 Lower Strainer and Valve Kit
Instructions-Parts
312749 XM Mix Manifold Kit
Instructions-Parts
313293 Alternator Conversion Kits
Instructions-Parts
313342 Dosing Valve Repair Kit
Instructions-Parts
313343 High Flow Severe Duty Shutoff Check
Valve Repair Kit Instructions-Parts

Warnings
4313289V
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks.
When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this
manual where applicable.
DANGER
SEVERE ELECTRIC SHOCK HAZARD
This equipment can be powered by more than 240 V. Contact with this voltage will cause death or
serious injury.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• This equipment must be grounded. Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Use equipment only in well-ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
• Do not connect USB device in explosive atmospheres.
SPECIAL CONDITIONS FOR SAFE USE
• To prevent the risk of electrostatic sparking, the equipment's non-metallic parts must be cleaned with
only a damp cloth.
• Refer to the Viscon HP Heater manual for special conditions for safe use.

Warnings
313289V 5
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
INTRINSIC SAFETY
Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment
will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local
regulations and the following safety requirements.
• Only models with model number XM_D_ _ or XM_E_ _, and packaged models with part numbers
ending in 00-13, 17-23, 27-29, 31, utilizing the air-driven alternator are approved for installation in a
Hazardous (explosive atmosphere) Location - see Approvals, page 11. Only the models stated
above meet all local safety fire codes including NFPA 33, NEC 500 and 516, and OSHA 1910.107.
To help prevent fire and explosion:
- Do not install equipment approved only for a non-hazardous location in a hazardous location.
See model ID label for intrinsic safety rating of your model.
- Do not substitute system components as this may impair intrinsic safety.
• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic
Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit
from the hazardous area when troubleshooting.
• Do not connect, download, or remove USB device unless unit is removed from the hazardous
(explosive atmosphere) location.
• If explosion-proof heaters are used, ensure wiring, wiring connections, switches, and electrical
distribution panel all meet flame-proof (explosion-proof) requirements.
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.
• Engage trigger lock when not dispensing.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
WARNING

Warnings
6313289V
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) from distributor or
retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or
swallowed.
• Read Safety Data Sheets (SDSs) for handling instructions and to know the specific hazards of the
fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area
well-ventilated and always wear appropriate personal protective equipment. See Personal
Protective Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
WARNING

Warnings
313289V 7
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing
equipment, or when in the work area. Protective equipment helps prevent serious injury, including
long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and
hearing loss. This protective equipment includes but is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority.
• Protective eyewear and hearing protection.
WARNING

Important Isocyanate (ISO) Information
8313289V
Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions Material Self-Ignition
Keep Components A and B
Separate
Spraying or dispensing fluids that contain isocyanates
creates potentially harmful mists, vapors, and
atomized particulates.
• Read and understand the fluid manufacturer’s
warnings and Safety Data Sheets (SDSs) to know
specific hazards and precautions related to
isocyanates.
• Use of isocyanates involves potentially hazardous
procedures. Do not spray with this equipment
unless you are trained, qualified, and have read
and understood the information in this manual and
in the fluid manufacturer’s application instructions
and SDSs.
• Use of incorrectly maintained or mis-adjusted
equipment may result in improperly cured
material. Equipment must be carefully maintained
and adjusted according to instructions in the
manual.
• To prevent inhalation of isocyanate mists, vapors,
and atomized particulates, everyone in the work
area must wear appropriate respiratory protection.
Always wear a properly fitting respirator, which
may include a supplied-air respirator. Ventilate the
work area according to instructions in the fluid
manufacturer’s SDSs.
• Avoid all skin contact with isocyanates. Everyone
in the work area must wear chemically
impermeable gloves, protective clothing and foot
coverings as recommended by the fluid
manufacturer and local regulatory authority.
Follow all fluid manufacturer recommendations,
including those regarding handling of
contaminated clothing. After spraying, wash
hands and face before eating or drinking.
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
Safety Data Sheets (SDSs).
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or damage
equipment. To prevent cross-contamination:
•Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.

Important Isocyanate (ISO) Information
313289V 9
Moisture Sensitivity of
Isocyanates
Exposure to moisture (such as humidity) will cause ISO
to partially cure, forming small, hard, abrasive crystal
that become suspended in the fluid. Eventually a film will
form on the surface and the ISO will begin to gel,
increasing in viscosity.
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO, the
humidity, and the temperature.
Changing Materials
NOTICE
Partially cured ISO will reduce performance and the life
of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and the
atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Always lubricate threaded parts with an appropriate
lubricant when reassembling.
NOTICE
Changing the material types used in your equipment
requires special attention to avoid equipment damage
and downtime.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing.
• Check with your material manufacturer for
chemical compatibility.
• When changing between epoxies and urethanes or
polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the B (resin) side.

Models
10 313289V
Models
Check the identification plate (ID) for the 6-digit part number of the sprayer. Use the following matrix to define the
construction of the sprayer, based on the six digits. For example, Part XM1A00 represents an XM Plural-Component
sprayer (XM); 5200 psi pump set with pump filters (1); wall power supply, no heaters, no junction box, and is not
approved for hazardous areas (A); with no additional kits (00).
NOTE: Some configurations in the following matrix cannot be built. Consult with distributor or Graco representative.
To order replacement parts, see Parts section in this manual. The digits in the matrix do not correspond to the Ref.
Nos. in the Parts drawings and lists.
Location Category Key:
NE Not for use in European explosive atmosphere locations or hazardous locations.
EH For use in explosive atmospheres and hazardous locations.
XM sprayers are not approved for use in hazardous
locations unless the base model, all accessories, all
kits, and all wiring meet local, state, and national
codes.
XM 1 A 00
First and
Second
Digits
Third Digit Fourth Digit
Fifth and
Sixth
Digits
System Choice
(See Table 1 for lower models)
Kit Choice Additional
Kit
Pump Set
(hose/gun)
Pump
Filters
Remote
Manifold
Control
Box
Fluid
Heaters
Junction
Box
Location
Category
Approvals
(See page 11
for approvals)
See Table
2 for
selections
XM
(plural
component
sprayer
mounted
on a frame)
15200 psi AWall Power
Supply NE CE, FM, FMc
25200 psi BWall Power
Supply 
NE CE, FM,
FMc
36300 psi CWall Power
Supply NE CE, FM, FMc
46300 psi DIS/
Alternator EH CE, FM,
FMc, Ex
55200 psi  EIS/
Alternator EH CE, FM,
FMc, Ex
65200 psi 
76300 psi 
86300 psi 

Models
313289V 11
Approvals
See appropriate column on page 10.
Table 1: Lower Models and Corresponding Identification Codes
Table 2: Additional Kits - Identification Code Index
See Repair and Spare Parts Reference, page 69, for more information. See Related Manuals, page 3, for kit
manual numbers.
XM _ A_ _
XM _ B_ _
XM _ C_ _
XM _ D_ _
XM _ E_ _
Code
System Pressure
(MPa, bar)
Pump
Filters
A Lower
(see your pump manual)
B Lower
(see your pump manual)
1 or 5 5200 psi (35, 350) L250C4 L220C4
2 or 6 5200 psi (35, 350) L250C3 L220C3
3 or 7 6300 psi (49, 490) L180C4 L145C4
4 or 8 6300 psi (49, 490) L180C3 L145C3
Intrinsically safe for
Class I, Division 1, Group D, T3
Ta = 0 °C to 54 °C
II 2 G
Ex db ib pxb IIA T3 Tamb = 0 ºC to 54 ºC
FM09ATEX0015X
See Special Conditions for Safe Use in Warnings, page 4.
20 Gal.
Hopper
Kit
Hopper
Heater
Kit 240V
Hopper
Fluid
Inlet Kit
Hopper
Universal
Mount Kit
Twistork
Agitator
Kit
T2 Pump
Feed Kit
(on
hopper)
5:1 Pump
Feed Kit
(on
hopper)
7 Gal.
Hopper
(Green)
and
Bracket
Kit
7 Gal.
Hopper
(Blue)
and
Bracket
Kit
Drum
Feed Kit
(Dual T2
and
Agitator)
Drum
Feed Kit
(Dual 5:1
and
Agitator)
Heated
Hopper/
Hose
Circulation
Kit
00
11 1111 1
13 111 11
14 111 1 1 1
15 11 111 1
16 11 11 11
17 1111 1 1
19 111 11 1
21 2222
23 222 2
24 222 2 2
25 22 222
26 22 22 2
27 2222 1
29 222 2 1
30 2
31 2
32 11

Overview
12 313289V
Overview
Before Repair
Location
Grounding
Connect ground wire clamp (FG) to a true earth ground.
If wall power is used to power controls or heaters,
ground electrical connection properly according to local
codes.
Proper Lifting of Sprayer
Lift Using a Forklift
Power must be off. Sprayer can be raised and moved
using a forklift. Carefully lift the sprayer; make sure it
balances evenly.
Lift Using a Hoist
Sprayer can also be lifted and moved using a hoist.
Connect a bridle swing, hooking an end to each of the
air motor lift rings. Hook the center ring to a hoist
Carefully lift the sprayer; make sure it balances evenly.
XM sprayers are not approved for use in hazardous
locations unless the base model, all accessories, all
kits, and all wiring meet local, state, and national
codes. See Models, page 10, to determine the
appropriate location for your particular model.
XM sprayers are not approved for use in hazardous
locations unless the base model, all accessories, all
kits, and all wiring meet local, state, and national
codes. See Models, page 10, to determine the
appropriate location for your particular model.
WLD
FG
Follow instructions to avoid serious injury or damage
to equipment. Never lift with the hopper(s) filled.
WLE
2.0 ft. (0.61 m)
minimum

Before Repair
313289V 13
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
Relieve A and B Fluid Pressure
1. Engage trigger lock.
2. Press .
3. If fluid heaters are used, shut them off using the
controls on the heater control box.
4. Shut off feed pumps, if used.
5. Remove and clean the spray tip.
6. Disengage trigger lock.
7. Hold a metal part of the gun firmly to a grounded
metal pail with a splash guard in place. Trigger gun
to relieve pressure in material hoses.
8. Engage trigger lock.
Relieve Pump Fluid Pressure
9. Close mix manifold valves (AH, AJ), then open
solvent flush valve (AK) on mix manifold.
10. Open solvent pump air control (CB). Use lowest
pressure needed to flush material out of hose.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
TI1949a
Fluid Heater A
Fluid Heater B
ti21275a
TI1950a
TI1953a
TI1949a
Replace with illustration
AH AJ
AK
312359 313289
CB

Before Repair
14 313289V
11. Disengage trigger lock.
12. Hold a metal part of the gun firmly to a grounded
metal pail with a splash guard in place. Trigger gun
to flush mixed material out of line with clean solvent.
13. Shut off solvent pump on air control panel.
14. Repeat steps 11 and 12. Then continue to step 15.
15. Close solvent flush valve (AK) on mix manifold.
16. Release any residual gun pressure and engage
trigger lock.
Flush Before Using Equipment
The equipment was tested with lightweight oil, which is
left in the fluid passages to protect parts. To avoid
contaminating your fluid with oil, flush the equipment
with a compatible solvent before use. See Flush on
page 15.
TI1950a
Replace with illustration
AK
TI1949a

Flush
313289V 15
Flush
Flush Mixed Material
Flush Mix Manifold
Use Solvent Pump
1. Press to turn off system. Follow Pressure
Relief Procedure, page 13. Engage trigger lock.
Remove spray tip.
2. Close sampling valves (AE, AF) and mix manifold
valves (AH, AJ).
3. Open solvent shutoff valve (AK) at mix manifold.
4. Open solvent pump air control (CB). Pull out and
slowly turn solvent pump air regulator (CG)
clockwise to increase air pressure. Use lowest
possible pressure.
5. Disengage trigger lock. Hold a metal part of the gun
firmly to a grounded metal pail with a splash guard
in place.Use a pail lid with a hole in it to dispense
through. Be careful to keep fingers away from the
front of the gun. Trigger gun until solvent appears.
6. Engage trigger lock.
7. Close solvent pump air valve (CB) and solvent
shutoff valve (AK) at mix manifold.
8. Follow Pressure Relief Procedure, page 13.
9. Engage trigger lock.
10. Disassemble and clean spray tip with solvent by
hand. Reinstall on the gun.
4)!
TI1949a TI1948a
AE AF
AJ
AH
AK
CG
CB
AK

Flush
16 313289V
Empty and Flush Entire System
(new sprayer or end of job)
NOTE:
• If system includes heaters and heated hose, turn
them off and allow to cool before flushing. Do not
turn on heaters until fluid lines are clear of
solvent.
• Use the lowest possible pressure when flushing to
avoid splashing.
• Before color change or shutdown for storage, flush
at a higher flow rate and for a longer time.
• To flush only mix manifold, see Flush Mix Manifold
procedure page 15.
Guidelines
Flush new systems if coating materials will be
contaminated by 10W oil.
Flush system when any of the following situations occur.
Flushing will help prevent materials from clogging the
line between hoppers and pump inlets.
• Anytime sprayer will not be used for more than one
week
• If materials used will settle
• If using thixotropic resins that require agitation
Procedure
1. Follow Pressure Relief Procedure, page 13, and
Flush Mixed Material, page 15, as required.
Engage trigger lock. Turn main pump air regulator
(CD) fully counter-clockwise to shut off.
NOTE: When flushing coating materials, remove pump
fluid filters, if installed, and soak in solvent to decrease
cleaning time. Proceed with Step 2. If flushing a new
system, leave filters in place.
2. Move circulation return lines to separate fluid
containers to pump remaining fluid out of system.
3. Increase main pump air regulator (CD) pressure to
30 psi (21 kPa, 2.1 bar).
4. Select . Press .
When running pumps independently set to or
. Press and as needed to clean.
NOTE: If sprayer does not start with static pressure,
increase air pressure by 10 psi (69 kPa, 0.7 bar)
increments. To avoid splashing do not exceed 40 psi (28
kPa, 2.8 bar).
air regulator
CD

Flush
313289V 17
5. Open recirculation valves (AC, AD) for respective
pump dispense side. Run pumps until the A and B
reservoirs are empty. Salvage the material in
separate, clean containers.
NOTE: When priming or flushing the pumps, it is normal
to get cavitation or pump runaway alarms. Clear the
alarms , and press again as necessary.
These alarms prevent excessive pump speeds that can
damage pump packings.
6. Wipe the reservoirs clean, then add solvent to each.
Move circulation lines to waste containers.
7. Repeat Step 4 to flush through each side until clean
solvent exits recirculation hose.
8. Stop and move recirculation hoses back to
reservoirs. Continue recirculating until machine is
thoroughly flushed.
9. Close recirculation valves (AC, AD) and open mix
manifold valves (AH, AJ). Dispense fresh solvent
through mix manifold valves and out gun.
10. Close mix manifold valves (AH, AJ).
11. Slowly open sampling valves (AE, AF) to flush
solvent through until clean. Close sampling valves.
Press .
12. Follow Pressure Relief Procedure, page 13.
13. Remove pump fluid filters, if installed, and soak in
solvent. Clean and replace filter cap. Clean filter
o-rings and leave out to dry. Do not leave o-rings in
solvent.
14. Close main air valve (E).
NOTE: Always leave some type of fluid, such as solvent
or oil, in the system to prevent scale build up. This build
up can flake off later. Do not use water.
AC AD
AD
AF
AJ
AC
AE
AH

Shutdown Entire System
18 313289V
Shutdown Entire System
Follow this procedure before prolonged shutdown or
before servicing equipment.
1. Follow Pressure Relief Procedure, page 13. Place
gun over pail. Trigger gun; wait until pumps are
down.
2. Engage trigger lock, turn off air regulator, and close
main air shutoff valve. Remove spray tip.
3. Follow flushing procedure, see Flush on page 15.
4. Follow Pressure Relief Procedure, page 13.
Engage trigger lock.
5. For prolonged shutdown (one week or longer):
- Follow flushing procedure, see Empty and
Flush Entire System (new sprayer or end of
job) on page 16.
- Cap fluid outlets to keep solvent in the lines.
- Fill pump A and B packing nuts with throat seal
liquid (TSL).
Cleaning Procedure
1. Ensure all equipment is grounded. See Grounding,
page 12.
2. Turn off all heaters and allow equipment to cool.
3. Flush mixed material. See Flush Mixed Material,
page 15.
4. Relieve pressure. See Pressure Relief Procedure,
page 13.
5. Shutdown sprayer and turn off all power. See
Shutdown Entire System, page 18.
6. Ensure the area where the sprayer will be cleaned
is well ventilated; and remove all ignition sources.
7. Clean external surfaces using only a rag soaked in
solvent that is compatible with the spray material
and the surfaces being cleaned.
8. Allow enough time for solvent to dry before using
sprayer.
TI1953a
4)!
TI1949a

Troubleshooting
313289V 19
Troubleshooting
NOTE: The sprayer operates using air pressure. Many
problems are caused by inadequate air supply. The inlet
air pressure gauge cannot drop below 50 psi (0.35 MPa,
3.5 bar) while running.
NOTE: If an error code displays, see manual XM
sprayer operation manual.
To avoid injury due to unexpected machine operation
initiated by a remote controller, disconnect the
customer I/O cable from the system prior to
troubleshooting.
Problem Cause Solution
Display not lit on system with
alternator power supply.
No electric power.
Air valve not turned on. Turn on main air valve to system.
Air supply pressure too low. Increase pressure to 30 psi (0.21 MPa, 2.1 bar)
or greater.
Air supply filters plugged. Inlet
manifold filter (604) or air regulator
(344) filter plugged.
Clean filter bowls; replace filter elements. Page
21.
Turbine air regulator (277) set too low. Adjust to 18 +/- 1 psi (12.6 +/- 10 kPa, 1.26 +/-
0.07 bar).
Alternator turbine failure. Repair or replace turbine. Page 28.
Power supply not connected to main
board.
Check power connections to main board. See
Electrical Schematics, starting on page 37.
Display board failure. Replace display board. Page 25.
Display not lit on system with
alternator power. Green light is
present on FCM (218) and USB (219),
but no green light is present on back
of display module (204).
Faulty CAN cable (268). Or CAN cable
is disconnected.
Check cable and replace. See Alternator
Assembly, page 62.
Faulty display module. Replace display module. See User Interface/
Control Box, page 22.
Display not lit on system with wall
power supply. No green light present
on back of display module (204).
No electric power. Disconnect “off” or
breaker “open.”
Reset main disconnect and breaker.
No green lights present on display,
FCM, or USB module.
Check for 24 Vdc on J1, pins 2 and 3, of power
supply. See Electrical Schematics, starting on
page 37. If there is not 24 Vdc, replace with
15V747.
No display power through CAN cable
(266). Green light in present on FCM
(218), but is not present on USB
module (219).
Check CAN cable. Replace if necessary. See
Wall Power Supply Assembly, page 63.
Green light is present on USB module
(219).
Check CAN cable (274). Replace if necessary.
See Wall Power Supply Assembly, page 63.
Display not lit on system with wall
power supply. Green light is present
on back of display module (204).
Display module failed. Replace display module. See User
Interface/Control Box, page 22.

Troubleshooting
20 313289V
Pumps do not run when Run Mode is
selected and the blue LED is
illuminated.
Air pressure to pumps too low. Increase pressure to 50 psi (0.35 MPa, 3.5 bar)
or greater.
Air pilot lines are obstructed. Check pilot lines for kinks or pinches.
Solenoid valve stuck. Actuate solenoid manually, if it does not
operate, replace solenoid. Page 22.
Air pilot valve(s) to motor stuck. Replace valve(s). Page 32.
Metering valve(s) not opening. Service or replace valve(s). Page 32.
Air motor stalled. See air motor manual.
Pump Test completes without error,
but A or B component has more than
750cc of fluid in beaker.
Incorrect pumps were selected in
System Setup screens.
See Appendix A, in your XM sprayer operation
manual.
Air is trapped in fluid due to excessive
agitation, circulation, and heat. Fluid is
measured by volume when it is
compressed under pressure.
Repeat Pump Test with fresh fluid.
If the specific gravity of each fluid is known,
check samples by weight (750cc x specific
gravity equals weight in grams).
If weight is correct, extra volume in beaker is
air.
Batch Test completes without error,
but A or B component has more fluid
in beaker than displayed on screen.
See causes for previous pump test
problem.
See solutions for previous pump test problem.
Sprayer does not start when start
button is pressed.
Faulty start switch or wire harness. Check start switch and wiring harness
continuity; switch is normally open circuit.
See Electrical Schematics, starting on page
37.
Faulty stop switch or wiring harness. Check stop switch and wiring harness
continuity; stop switch is normally closed circuit.
See Electrical Schematics, starting on page
37.
Fluid valves leaking. Loose or worn packings. Tighten packing nut. If leak continues, replace
packings.
Paint does not cure consistently. Ratio not set correctly. Check that correct ratio is set and set by
volume. See XM sprayer operation manual.
Material not mixing correctly. Test pump. Make sure mixer is clean; flush as
needed. See XM sprayer operation manual.
Position mixer after integrator hose.
Material not properly conditioned
before it was added to sprayer.
Mix material thoroughly.
Not using enough integration hose. Add more integration hose.
Select “fast dosing” in setup.
Poor spray pattern. Fluid pressure too low. Increase pump pressure.
Fluid temperature too low. Increase fluid temperature.
Spay tip dirty or worn. Relieve pressure. Clean or replace tip. Follow
gun manual instructions.
Fluid A and B fitters plugged. Clean filters. See pump manual.
Mixer hoses partially plugged or too
restrictive.
Inspect parts for cured material. Clean or
replace, or use larger hoses and mixer.
Problem Cause Solution