Repair - Parts 004G EN Self-contained, single color, electronic plural component paint proportioner, with carbon steel UltraMix Pump and cart. For professional use only. 50 psi (.7 MPa, 7 bar) Maximum Fluid Working Pressure Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. Model 490 Clear Coat System Shown See page for model information, including maximum working pressure. TI684a Conforms to FM std 600 & 60 for use in Class I Div Group D T Hazardous Locations CAN/CSA. No. 57-9 & No. 00.-9
Contents Manual Conventions........................ ProMix Easy Models........................ Related Manuals........................... Warnings................................. 4 Pressure Relief Procedure (Models 490 and 49)................................ 6 Fluid Manifold to Gun..................... 6 Pump to Fluid Manifold.................... 7 Pressure Relief Procedure (Model 5896)...... 8 Fluid Manifold to Gun..................... 8 Pump to Fluid Manifold.................... 9 Maintenance.............................. 0 Preventive Maintenance Schedule.......... 0 Dispense Valve......................... 0 Pump................................. 0 Turbine Alternator....................... 0 Air Filters.............................. 0 Pump Test............................. 0 Wet Cup.............................. 0 Storage............................... 0 Troubleshooting........................... Alarms.................................. 4 Repair................................... 6 Replacing Air Filter Element............... 6 User Interface.......................... 7 Pneumatic Control...................... 0 Dispense Valve Assembly................. Pump Assembly........................ Remote Mix Manifold and Fluid Regulator (490 and 49 only)............. Electrical Schematic....................... 4 Main Control Board Schematic............... 5 Parts.................................... 6 Part No. 490 Clear Coat System, Series A (shown)............................ 6 Part No. 49 Primer System, Series A..... 6 Part No. 5896 Primer System, Series A (shown)............................ 0 Part No. 490 Proportioner, Series A....... 4 Pneumatic Schematic..................... 40 870 Pump Air Control.................. 4 4870 Intrinsically Safe Pneumatic Control... 4 460 User Interface.................... 44 499 Pump Inlet Valve Assembly, for 490 Clear Coat System only....... 45 498 Pump Outlet Valve Assembly, for 490 Clear Coat System only....... 45 496 Dispense Valve Assembly, for 490 Clear Coat System........... 46 4987 Dispense Valve Assembly, for 49 Primer System.............. 47 49 Hose Bundle and Remote Mix Manifold, for 490 Clear Coat System........... 48 4986 Hose Bundle and Remote Mix Manifold, for 49 Primer System.............. 49 440 Remote Mix Manifold (490 and 49 only)........................ 50 Technical Data............................ 5 Graco Standard Warranty................... 5 Graco Information......................... 5 004G
ProMix Easy Models ProMix Easy Models Approved for Hazardous Location Class I, Div, Group D (North America) ProMix Easy Part No. Series Description and Approvals 490 A Clear coat system; cart mount, UltraMix carbon steel pumps, and remote mix manifold 49 A Primer system; cart mount, UltraMix carbon steel pumps, and remote mix manifold 5896 A Primer system; cart mount, UltraMix carbon steel pumps, standard mix manifold, and automatic flush valves Maximum Working Pressure psi (MPa, bar) 50 (.7, 7) 50 (.7, 7) 50 (.7, 7) Related Manuals Manual Description 00 ProMix Easy Operation Manual 0655 Dispense Valve 066 Displacement Pumps 067 UltraMix Pumps 067 Circulation Kits 0674 Mounting Kits 0675 AC Power Supply 0678 TSL Pump Kits 0800 Auto Flush Kit 0700 Gun Air Regulator Kits Manual Description 44 AirPro Pressure Feed Airspray Gun 096 Data Download Kits 0804 Turbine Alternator Repair Kit 0867 Low Volume Air Regulators 0869 Pressure Tanks 087 Agitators 0875 Pressure Tank Bottom Outlet Kit 0855 Husky 07 AODD Pumps 07 Fluid Pressure Regulators 004G
Warnings Warnings The following general warnings are related to the safe setup, use, grounding, maintenance and repair of this equipment. 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 power or light switches on or off when flammable fumes are present. Ground all equipment in work area. See Grounding instructions. 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. PRESSURIZED EQUIPMENT HAZARD Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury. Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment. Tighten all fluid connections before operating the equipment. Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. 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 kink or overbend hoses or use hoses to pull equipment. Comply with all applicable safety regulations. 4 004G
Warnings WARNING 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 equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply. 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 004G 5
Pressure Relief Procedure (Models 490 and 49) Pressure Relief Procedure (Models 490 and 49) WARNING Fluid Manifold to Gun Relieve pressure from fluid manifold to gun whenever you stop spraying and before servicing gun or removing spray tip. In addition, relieve pressure from pump to fluid manifold at end of day and before cleaning, checking, or servicing pump, manifold, or fluid line accessories or transporting equipment. Read warnings, page 4.. Press.. Close all valves at mix manifold.. Hold a metal part of the gun firmly to a grounded metal pail. Trigger gun to relieve pressure. TI486a 6 004G
Pressure Relief Procedure (Models 490 and 49) Pump to Fluid Manifold. Open all fluid valves at mix manifold. Leave solvent valve (S) closed. 5. Hold a metal part of the gun firmly to a grounded metal pail. Trigger gun to relieve component A pressure. Indicator A will stay on for 5 sec after Pump A reaches Park position, then go off. TI486a S. Open all fluid outlet valves. TI644a 6. Indicator B comes on and Pump B pressurizes. 7. Hold a metal part of the gun firmly to a grounded metal pail. Trigger gun to relieve component B pressure. Indicator B will stay on for 5 sec after Pump B reaches Park position, then go off.. Turn function knob to pressure relief/park. TI486a If both pumps are not parked after min, Alarm 6 will sound. 4. Press. Indicator A comes on, and Pump A pressurizes. 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. 004G 7
Pressure Relief Procedure (Model 5896) Pressure Relief Procedure (Model 5896) WARNING 5. Engage trigger lock. Relieve pressure from fluid manifold to gun whenever you stop spraying and before servicing gun or removing spray tip. In addition, relieve pressure from pump to fluid manifold at end of day and before cleaning, checking, or servicing pump, manifold, or fluid line accessories or transporting equipment. Read warnings, page 4. Fluid Manifold to Gun. Engage trigger lock.. Press.. Disengage trigger lock. 4. Hold a metal part of the gun firmly to a grounded metal pail. Trigger gun to relieve pressure. 8 004G
Pressure Relief Procedure (Model 5896) Pump to Fluid Manifold. Close shutoff valves G A and G B.. Place waste container under sampling valves H A and H B. 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 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. H B G B H A G A TI586a 6. Indicator B comes on and Pump B pressurizes.. Turn function knob to pressure relief/park. 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. Indicator A comes on, and Pump A pressurizes. If both pumps are not parked after min, Alarm 6 will sound. 8. Close sampling valves A and B before restarting system. 004G 9
Maintenance Maintenance Preventive Maintenance Schedule Establish a preventive maintenance schedule, based on the pump s repair history. Dispense Valve See dispense valve manual 0655. Pump See applicable pump manual 067 or 066. Turbine Alternator Replace bearings every 000 hours. See page 0. Air Filters Drain and clean as necessary. See page 6. Pump Test See ProMix Easy Operation manual. If pumps fail test, see Icing, page 0. Wet Cup Check pump wet-cups daily. Keep filled with Graco Throat Seal Liquid (TSL), Part No. 06995. Storage Before storing the pump, always flush it, see ProMix Easy Operation manual. Relieve the pressure, page 6. Icing 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. Reduce moisture in compressed air supply, or use heated air. If icing persists, see table below. Problem Solution Pump slows on both up and down stroke. Turn D port bleed screw 60 (/6 turn) counterclockwise, to bleed cfm air to melt ice. Pump slows on down stroke. Turn D port bleed screw 60 (/6 turn) counterclockwise, to bleed cfm air to melt ice. If icing continues, turn screw to 90 (/4 turn) to increase air flow to cfm. If necessary, increase air flow to cfm by turning screw to 70 (/4 turn). Do not exceed cfm (/4 turn maximum). U D Pump slows on up stroke. Turn U port bleed screw 90 (/4 turn) counterclockwise, to bleed cfm air to melt ice. If icing continues, turn screw to 0 (/ turn) to increase air flow to cfm. If necessary, increase air flow to cfm by turning screw to 80 (/ turn). Do not exceed cfm (/ turn maximum). TI594a 0 004G
Troubleshooting Troubleshooting WARNING If an alarm code displays, see page 4. Read warnings, page 4-5. Display not lit. No electric power. Problem Cause Solution Air valve not turned on. Turn on main air valve to system. Air supply pressure too low. Increase pressure to 60 psi (0.4 MPa, 4. bar) or greater. Air supply filters plugged. Clean filter bowls; replace filter elements. Page 6. Turbine air regulator set too low. Adjust to proper setting. Turbine alternator failure. Repair or replace turbine. Page 0. Power supply not connected to main board. Main board not connected to display board. Check power connections to main board. See Electrical Schematic, page 4. Check electrical connections between display and main board. See Electrical Schematic, page 4, and Main Control Board Schematic, page 5. Display board failure. Replace display board. Page 9. Pumps do not run. Air pressure to pumps too low. Increase pressure to 50 psi (0.5 MPa,.5 bar). Solenoid valve stuck. Actuate solenoid manually, if it does not operate, replace solenoid. Page. Dispense valve(s) not opening. Service or replace valve(s). See 0655. Pump test volume is not correct. Air pressure to pumps too low Increase pressure to 50 psi (0.5 MPa,.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 067. Pump cavitating excessively. Check for air in siphon lines caused by loose fitting or use of agitator. Material too viscous. Use heater. 004G
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. Test pump. Page 0. Make sure mixer is clean; flush as needed. See ProMix Easy Operation manual. Pump not operating correctly. Observe whether pumps are loading and checking correctly, if not, clean and repair pump. See displacement pump manual 066. Poor spray pattern. Fluid pressure too low. Increase pump pressure. Spray tip dirty or worn. Relieve pressure. Clean or replace tip. Follow gun manual instructions. Fluid A or B filters plugged. Clean filters on siphon tube in tank. Mixer or hoses partially plugged. Inspect parts for cured material. Clean or replace. System runs erratically. Air filter(s) clogged. Replace elements. Clean. Replace element(s). See page 6. Air supply hoses undersized. Replace hoses with appropriate size. Air compressor undersized. Use larger air compressor. Air supply pressure tank undersized. Use larger pressure tank. Air supply relief valve opens. Turbine air regulator set too high. Lower setting to -5 psi (7-4 kpa,.7-.4 bar). Turbine alternator makes high-pitched whining noise. Display shows 88888 or unit reboots unexpectedly. ProMix Easy does not start when start button is pressed. Turbine bearings worn. (Setting turbine air regulator too high, wears bearings.) Turbine is not supplying enough power to board. Replace bearings. Page 0. Increase turbine regulator setting to -5 psi (7-4 kpa,.7-.4 bar). Check turbine and electrical control exhaust air for restrictions. Replace turbine bearings. Page 0. Faulty start switch or wire harness. Check start switch and wiring harness continuity; switch is normally open circuit. See Electrical Schematic, page 4. Faulty stop switch or wiring harness. Check stop switch and wiring harness continuity; stop switch is normally closed circuit. See Electrical Schematic, page 4. Bad I/O port on display board. Replace board. Page 9. Bad I/O port on main board. Replace board. Page 8. Dispense valves leaking. Loose or worn packings. Tighten packing nut. If leak continues, replace packings. See 0655. 004G
Troubleshooting Problem Cause Solution Flow rate too low, or no flow. Inadequate air supply. Use larger CFM compressor. Air pressure to pumps too low. Increase pressure. Fluid A or B filters plugged. Clean filters on siphon tube in tank. Mixer or hoses partially plugged. Inspect parts for cured material. Clean or replace. Insufficient dispense valve travel. Increase travel. See 0655. Shutoff valves are not fully open. Ensure that shutoff valves are fully open and sampling valves are closed. Fluid regulator on remote mix manifold is set to high pressure position. Set regulator to lower pressure position. Pump stops after cycles. Knob is set to Run pump A or B independently. if spraying mate- Turn knob to spray rial. 004G
Alarms Alarms * Indicates error where audible alarm sounds once briefly. ** Indicates error where audible alarm sound pulses. Code Alarm Active Problem Cause Startup Errors 0 Sensor Error A* Always No signal from pump A sensor 0 Sensor Error B* Always No signal from pump B sensor 0 Communication Error* Always Loss of communication between main and display boards Operating Errors 04 not used 05 not used 06 Pump Error A** Spray 07 Pump Error B** Test Batch Pump does not stall after top change over Pump cavitating excessively 08 Sensor Code Error Always Sensor values reverted to default 09 not used 0 not used Sensor Reading Low A* Spray Pump stroke travels Sensor Reading Low B* Test beyond sensor range at Batch top change over Sensor Reading High A* Spray Pump stroke travels 4 Sensor Reading High B* Test beyond sensor range at Batch bottom change over Pot Life Error Spray Pot life timer timed out first, then Always Loose cable, failed sensor or cable, failed magnet assembly Loose cable, failed sensor or cable, failed magnet assembly Loose cable, failed board Intake valve leak Air in siphon lines caused by loose fitting or use of agitator Empty fluid supply Sensor value data corrupt; board needs replacement and /or recalibration Sensor or bracket loose Sensor magnet dirty Sensor or bracket loose Sensor magnet dirty Not enough material sprayed after last reset 4 004G
Alarms Code Alarm Active Problem Cause Operating Errors (continued) not used not used 4 not used 5 not used 6 Park Timeout Park Pumps not at bottom of stroke Testing Error Sampling valves closed, or gun not triggered. 5 Piston packing/ball A* Test Pump does not completely Piston packing or ball check failure 6 Piston packing/ball B* stall in up stroke 7 Inlet Ball A* Test Pump does not completely Intake valve ball check failure 8 Inlet Ball B* stall in downstroke 9 Dispense Valve A* Test Pump does not completely Throat packing or dispense valve failure stall in both up 0 Dispense Valve B* and down strokes 7 Pump Calibration Timeout A 8 Pump Calibration Timeout B Run A Run B Pump doesn t run through calibration. Sampling valves closed. 004G 5
Repair Repair Flush before repairing equipment, if possible. See Pro- Mix Easy Operation manual. WARNING Read warnings, page 4. Follow Pressure Relief Procedure (Models 490 and 49), page 6, if service time may exceed pot life time, before servicing fluid components, and before transporting equipment to a service area.. Close main air shutoff valve on air supply line and on unit.. Remove left side plate ().. Unlock filter bowl guard and remove. 4. Unscrew filter bowl. Replacing Air Filter Element There are air filters on the unit: the 5 micron air manifold filter (7) and 40 micron pump air filter (9). Replace element as needed. Order 5D909 5 micron filter and 5D890 40 micron filter. WARNING 5. Remove and replace element. 6. Screw filter bowl on securely. 7. Reassemble. Removing the bowl of a pressurized air filter could cause serious injury. Do not service air filter until air line is depressurized. 6 004G
Repair User Interface Removal. Close main air shutoff valve on air supply line and on unit.. Remove side panels ().. Remove fasteners (45). Gently pull user interface () away from pneumatic control (0). 5 0 45 Software Upgrades CAUTION To avoid damaging circuit board, wear a grounding strap.. Remove User Interface cover. See above.. Use a chip remover (D) to remove software chip (C). FIG.. C D FIG.. Install new chip (beveled corner down). FIG. TI6506a 4. To completely remove user interface (), disconnect ground wire (5), and wires (46 and 406) from main control board (0). See Electrical Schematic, page 4. 4. Reassemble. 5. Recalibrate main circuit board. See ProMix Easy Operation Manual. 004G 7
Repair Replacing Main Circuit Board CAUTION To avoid damaging circuit board, wear a grounding strap. 0. Remove User Interface cover. See page 7.. Disconnect all wire connectors from board (0). FIG.. 0. Remove four screws (0) and replace board (0). 4. Reassemble. Refer to Electrical Schematic, page 4. 5. Recalibrate system. See ProMix Easy Operation Manual. TI456a FIG. 8 004G
Repair Replacing Display Circuit Board CAUTION To avoid damaging circuit board, wear a grounding strap.. Remove User Interface cover. See page 7.. Disconnect wires from display board (40). FIG. 4.. Remove two screws (4). 4. Loosen setscrew (49) from knob (405) and remove knob assembly. Remove jam nut (N). 5. Remove and replace display board (40). 6. Reassemble. Refer to Electrical Schematic, page 4. 404 4 48 407 N 40 4 406 405 49 407 40 40 40 TI4755a 46 406 TI4756a 46 FIG. 4 004G 9
Repair Pneumatic Control Alternator Repair Turbine Alternator Repair Kit 688 is available to replace turbine bearings.. Remove User Interface cover. See page 7. Lightly lubricate turbine o-ring before installing turbine in housing. Connect alternator red wire to + side and black wire to side of main circuit board. Connect turbine to -pin connector on main circuit board. P 04 06r 0 05 04 04d 0 0 FIG. 6 FIG. 5 TI456a 04d 04a A. Disconnect power supply wires (P). FIG. 5.. Disconnect two air lines (0) from alternator (04). FIG. 6. 4. Remove top nut (05) and loosen bottom nut. Slide alternator up and off bottom nut. 04e 5. Remove four screws (04d) to separate alternator housings. FIG. 7. 6. Disconnect turbine (04e) from board (A). Follow instructions in turbine kit manual 0804 to remove and repair turbine. FIG. 7 Torque to 0 in-lbs ( N m) 7. Replace gasket (04a) if damaged. Place between housings before securing with screws (04d). 8. Reassemble. Refer to Electrical Schematic, page 4. 0 004G
Repair Replacing Solenoids Follow this procedure to replace a single solenoid.. Remove User Interface cover. See page 7.. Disconnect two solenoid wires (V) from main board. FIG. 8.. Disconnect dispense valve pilot lines (A, A, B, B). FIG. 8. 4. Remove two screws (S). 5. Remove and replace solenoid (06b). From left to right, solenoid functions are as follows: Component A Component B 6. Reassemble. Solenoid wires are polarized (red +, black ). Refer to Electrical Schematic, page 4. Replacing Alternator Regulator. Remove User Interface cover. See page 7.. Remove two screws (09) from the back of the control box.. Disconnect supply and exhaust air lines (0). FIG. 5, page 0. 4. Disconnect solenoid wires position Phoenix connector (06r) from main board. 5. Remove solenoid module (06) with regulator (06e). FIG. 8. 6. Unscrew and replace regulator (06e). 7. Reassemble. Refer to Electrical Schematic, page 4. Make sure gaskets (06j, 06k) are in place when reinstalling solenoid module. 8. Set regulator to 4 psi (60 kpa,.6 bar). Replacing Alarm. Remove User Interface cover. See page 7.. Disconnect alarm wires from main board.. Unscrew alarm () and replace. FIG. 5, page 0. 4. Reassemble. Refer to Electrical Schematic, page 4. Dispense Valve Pilot Lines A (off), clear tube A (on), black tube B (off), green tube B (on), red tube Set regulator pressure to 4 psi (60 kpa, 6 bar). Safety relief valve (06t) is required on all IS units. 0 06e A B B V A 06k 06j B 06t FIG. 8 TI6605a A A B S 06b TI4558a 004G
Repair Dispense Valve Assembly/Mix Manifold Assembly See the Parts drawing for your model. WARNING Pump Assembly See the Parts drawing for your model. WARNING Read warnings, page 4. Read warnings, page 4.. Follow Pressure Relief Procedure (Models 490 and 49), page 6, or Pressure Relief Procedure (Model 5896), page 8.. Label all air and fluid lines, and disconnect from fittings on manifold assembly.. Remove fasteners. 4. Remove mix manifold (). 5. To repair mix manifold, see manual 0654. To repair dispense valves, see manual 0655. 6. Reassemble.. Follow Pressure Relief Procedure (Models 490 and 49), page 6, or Pressure Relief Procedure (Model 5896), page 8.. Remove side plates ().. Remove wire harnesses from sensor and solenoids. Refer to Electrical Schematic, page 4. 4. Disconnect fluid inlet and outlet lines from pump lower. Disconnect air supply from pump. 5. Label all tubing and disconnect from fittings on pump assembly. 6. Remove mounting hardware and slide pump out of frame. 7. Repair as instructed in pump manuals 067, 067, or 066. 8. Reassemble. 004G
Repair Remote Mix Manifold and Fluid Regulator (490 and 49 only) Repair Kit 440 is available. Order the kit separately. Parts included in the kit are marked with a symbol, for example (90 ). WARNING Read warnings, page 4.. Follow Pressure Relief Procedure (Models 490 and 49), page 6.. Remove the four short screws (90) and one long screw (9) holding the fluid regulator housing (906) to the regulator mounting plate (90). Remove the fluid regulator housing, spring (9), and retainer (90). See FIG. 9.. Remove the remaining long screws (9) holding the regulator mounting plate (90), mix manifold housing (90), and base (905) together. Separate the three parts. 4. Remove the two gaskets (90, 904) from the mix manifold housing (90). 5. Hold the nut (99) with a wrench and unscrew the valve stem (9). Disassemble the acetal washer (98), diaphragm (97), large gasket (96), small gasket (95), and metal washer (94). 6. Clean all parts and replace any damaged parts. 7. Place the gaskets (90, 904 ) in the grooves of the mix manifold housing (90). Align the indexing pin on the base (905) with the small hole in the housing (90), and assemble the two parts. 8. Reassemble the diaphragm assembly in the reverse order, following the notes in FIG. 9. Be sure the AIR SIDE of the diaphragm (97 ) faces up toward the nut (99 ). 9. Reassemble the remaining parts in the reverse order, following the notes in FIG. 9. 9 4 9 IMPORTANT: Apply thread adhesive. IMPORTANT: Torque to 6-0 in-lb (0.7-. N m). Lubricate. 4 Torque to 50-60 in-lb (5.7-6.8 N m). 90 90 90 904 905 Google.url 9 9 9 909 90 4 907 908 5 AIR SIDE must face up, toward nut (99). 9 4 906 90 9 99 98 90 9 97 95 94 5 98 96 TI6509a FIG. 9. Mix Manifold and Fluid Regulator (490 and 49 only) 004G
Electrical Schematic Electrical Schematic MAIN CONTROL BOARD 4849 J6 JUMPER (5V) 0 J5 0 J4 0 0 4 4 5 5 6 6 7 7 8 8 J J J8 8 8 5VDC RED COM BLACK VDC RED RED BLACK RED BLACK - SOLENOID VALVE A - SOLENOID VALVE B FLUID VALVES BLACK SHIELD RED BLACK - CABLE # 4 OPT. SOLENOID, RECIRC. 5580 RED BLACK BLACK VDC SHIELD WHITE_W/GRN GREEN WHITE_W/ORANGE ORANGE WHITE_W/BLUE BLUE CABLE # 5D607 (X) WHITE_W/GRN GREEN WHITE_W/ORANGE ORANGE WHITE_W/BLUE BLUE SENSOR 4678 "A" SENSOR 4678 "B" SHIELD 6 RED WHITE BLACK CABLE # 5A854 (MAIN TO DISPLAY) J SIGNAL A WHITE COM METER A BLACK VDC 468 RED SIGNAL B METER B WHITE ORANGE AIR FLOW SWITCH 959 7 SOLENOID BOARD 5C75 P4 P S G ALARM ASSY 5A849 DISPLAY BOARD 45706 POWER SUPPLY ASSEMBLY 45 POWER SUPPLY POWER BARRIER SUPPLY BOARD 9790 RED BLACK RED BLACK RED BLACK RED BLACK - MOTOR B DOWN - MOTOR B UP - MOTOR A DOWN - MOTOR A UP 5D794 ALARM + ALARM COM RED WHITE BLACK COMM PORT ASSY 5A850 J RED WHITE BROWN GREEN BLACK J BLACK RED GREEN FRONT PANEL COM PORT RS CONNECTOR TX RX GND START A B LIGHT + - AIR INPUT GND KEY SWITCH MOM. STOP COM PORT PIN LOCATIONS FRONT SIDE VIEW (OPPOSITE SIDE OF SOLDER CUPS) START/STOP SWITCH ASSY 5A85 GND KEY SWITCH ASSY 5A85 4 5 6 7 8 9 4 5 6 7 8 9 4 5 6 7 4 5 6 4 5 6 7 4 5 6 7 8 9 4 5 6 7 8 9 4 5 6 7 4 5 6 7 4 5 6 + + + 5 4 6 5 4 6 4 5 6 4 5 6 4 5 6 7 8 4 5 + + + + 4 5 7 4 8 4 004G
Main Control Board Schematic Main Control Board Schematic J5 J6 F U4 MAIN CONTROL BOARD J4 J J8 J 004G 5
Parts Parts Part No. 490 Clear Coat System, Series A (shown) Part No. 49 Primer System, Series A 6 0 4 0 4 5 46 06 07 08 4 8 48 0 04 8 0 6 See page 8. 49 48 TI6505a See page 8. 7 TI685a 6 004G
Parts Part No. 490 Clear Coat System, Series A Part No. 49 Primer System, Series A Ref. No. Part No. Description Qty. 0 490 PROPORTIONER; see page 4 0 498 OUTLET VALVE ASSEMBLY; clear coat system only; see page 45 0 496 DISPENSE VALVE ASSEMBLY; clear coat system; see page 46 4987 DISPENSE VALVE ASSEMBLY; primer system; see page 47 04 499 PUMP INLET VALVE ASSEMBLY; clear coat system only; see page 45 05* 5F685 TRAY, feed tank 06 498 TANK, feed; clear coat system 498 TANK, feed; primer system 07 56589 UNION, adapter, 90 ; /4 npt(f) x /4 npsm(f); clear coat system 56589 UNION, adapter, 90 ; /4 npt(f) x /4 npsm(f); primer system 08 00505 BUSHING, pipe; /4 npt(m) x /8 npt(f); clear coat system 00505 BUSHING, pipe; /4 npt(m) x /8 npt(f); primer system 09* 5E04 BASE 0 5D986 PLATE, rear * 6698 VALVE, ball; /4 npt(m) x /4 4 npt(f) * 09 CONNECTOR, pipe; /4 npt (fbe) * 049 ELBOW, 90 ; /4 npt (mbe) 5* 5E04 SUPPORT, bracket 6* 66 CASTER 4 7 065 WASHER, lock; /8 8 8* 096 SCREW, cap; 5/6-8 x /4 in. 4 (9 mm) 9* 0996 NUT, hex, flanged; 5/6-8 4 0* 695 SCREW, cap; /8-6 x in. (76 mm) * 5F78 BRACKET, tank * 599 NIPPLE; / npt x /8 npt * 48 HOSE, siphon, solvent pump 4 984 TUBE, dryer; package of 4 5 474 MUFFLER; clear coat system 474 MUFFLER; primer system 6 48588 KIT, air regulator, gun; see 0700 7 49 HOSES/MANIFOLD; clear coat system; see page 48 4986 HOSES/MIX MANIFOLD; primer system; see page 49 8 0569 HOSE, fluid; /8 npsm (fbe); nylon; /8 in. (0 mm) ID; 6 in. (95 mm); clear coat system Ref. No. Part No. Description Qty. 0569 HOSE, fluid; /8 npsm (fbe); nylon; /8 in. (0 mm) ID; 6 in. (95 mm); primer system 9* 0959 CROSS, pipe; /4 npt(f) 0* 00840 ELBOW, street; /4 npt(m) x /4 npsm(f) * 645 NIPPLE; /4 npt x /4 npsm * 6598 NIPPLE, reducing; /8 npt x /4 npt * D9 PUMP, double diaphragm, solvent; see 0855 4 6485 NIPPLE; /8 npt x /8 npsm 4 5* 480 HOSE, fluid; /4 npsm (fbe); /4 in. (6 mm) ID; nylon; ft (0.9 m) 6* 94 SCREW, cap; /8-6 x in. (5 mm) 7* 958 NUT, hex, flange hd; /8-6 4 8* 5F676 LEG, stand 9* C94 CONNECTOR; /4 npt(m) x /8 in. (0 mm) OD tube 40 5F709 STRAP, feed tank (not shown) 4 99 SCREW, self-tapping 0 4 06966 HOSE, fluid; /4 npsm (fbe); PTFE; /4 in. (6 mm) ID; 8 in. (457 mm) 45 9798 CONNECTOR, tee; /8 in. (0 mm) OD tube 46 796 SCREW, cap, hex flanged hd; /4-0 x /4 in. (9 mm) 48 594 NUT, hex, flange hd; /4-0 6 49 000 SCREW, cap, hex hd; /4-0 x in. (5 mm) 4 57 buy locally TUBE; nylon; /8 in. (0 mm) OD; 4.5 see pages 6 and 40 ft 58 584 ELBOW; /4 npt(m) x /8 in. (0 mm) OD tube 59 0464 FITTING, bulkhead 60 9 FITTING, air; /4 npt(m) x /8 in. (0 mm) OD tube 6 C8 ELBOW; / npt(m) x /8 in. (0 mm) OD tube fitting 6 6750 TUBE; nylon; /4 in. (6 mm) ID * These parts are shown on page 8. These parts are shown on page 4. 004G 7
Parts Part No. 490 Clear Coat System, Series A, Detail Views Part No. 49 Primer System, Series A, Detail Views Solvent Pump Detail 5 9 9 0 TI6504a Base and Stand Detail 0 6 7 8 8 05 5 6 8 7 9 6 9 09 6 7 TI650a 7 8 004G
004G 9 Parts
Parts Part No. 5896 Primer System, Series A (shown) 0 0 6 44a TI58a 64 74 8 8 75 4 84 See Detail A, page. 07 08 4 8 06a 4 7 7 4 6 44c 5 56 0 See Detail B, page. 84 06b 44b See Detail D, page. 49 88 8 4 08 89 TI58a 08 4 8 48 See Detail C, page. 7 0 004G
Parts Part No. 5896 Primer System, Series A Ref. No. Part No. Description Qty. 0 490 PROPORTIONER; see page 4 0 459 MIX MANIFOLD; see manual 0654 06a 4E5 TANK, feed, component A; 5 gal. (57 l); with agitator and bottom outlet kit; see manual 0869 06b 4E56 TANK, feed, component B; 5 gal. (9 l); with bottom outlet kit; see manual 0869 07 56589 UNION, adapter, 90 ; /4 npt(f) x /4 npsm(f); clear coat system 08 00505 BUSHING, pipe; /4 npt(m) x /8 4 npt(f); clear coat system 09* 5E04 BASE 0 5D986 PLATE, rear * 6698 VALVE, ball; /4 npt(m) x /4 npt(f) * 049 ELBOW, 90 ; /4 npt (mbe) 5* 5E04 SUPPORT, bracket 6* 66 CASTER 4 8* 096 SCREW, cap; 5/6-8 x /4 in. (9 6 mm) 9* 0996 NUT, hex, flanged; 5/6-8 6 * 599 NIPPLE; / npt x /8 npt * 48 HOSE, siphon, solvent pump 6 48588 KIT, air regulator, gun; see 0700 7 58997 HOSE BUNDLE; /8 in. (0 mm) ID air hose, /4 npsm (fbe); /6 in. (5 mm) ID fluid hose, /8 npsm (fbe); 6 ft (8 m) 8 0598 HOSE, fluid; /8 npsm (fbe); nylon; /8 in. (0 mm) ID; 6 ft (.8 m) 0* 858 ELBOW; /8 npt x /4 npt (mbe) * D PUMP, double diaphragm, solvent; see 0855 4 6485 NIPPLE; /8 npt x /8 npsm 4 5* 480 HOSE, fluid; /4 npsm (fbe); /4 in. (6 mm) ID; nylon; ft (0.9 m) Ref. No. Part No. Description Qty. 6* 94 SCREW, cap; /8-6 x in. (5 6 mm) 7* 958 NUT, hex, flange hd; /8-6 6 8* 5E09 LEG, stand 9* 58 CONNECTOR; /4 npt(f) x /8 in. (0 mm) OD tube 4 99 SCREW, self-tapping 8 4 06966 HOSE, fluid; /4 npsm (fbe); PTFE; /4 in. (6 mm) ID; 8 in. (457 mm) 44 49076 AUTO FLUSH KIT; see manual 0800; includes items 44a-44c 44a 5E9 CONTROL BOX, auto flush 44b 87 VALVE, flush; see manual 0655 44c 55570 UNION, swivel; /4 npt(f) x /4 npsm(f) 45 9798 CONNECTOR, tee; /8 in. (0 mm) OD tube 48 594 NUT, hex, flange hd; /4-0 7 49 000 SCREW, cap, hex hd; /4-0 x 4 in. (5 mm) 55* 777 TEE; /8 npt(m) x /8 npt(f) x /8 npt(f) 56* 645 NIPPLE; /4 npt x /4 npsm 4 57 59085 TUBE; nylon; /8 in. (0 mm) OD;.5 see pages 8 and 40 ft 6 6750 TUBE; nylon; /4 in. (6 mm) ID 6* 409 ELBOW; /4 npt(m) x /4 in. (6 mm) OD tube 64 54896 TEE; 5/ in. (4 mm) OD tube 65 95 SCREW, cap, button hd; /4-0 x /8 in. (0 mm) 66 C908 WASHER, lock; /4 * These parts are shown on page. These parts are shown on pages 0 and. These parts are shown on page 4. 004G
Parts Ref. No. Part No. Description Qty. 67* 87874 GAUGE, fluid pressure 68* 007 ELBOW; /8 npt (mbe) 69* 559 NIPPLE, reducing; /4 npt x /8 npt 70* 4475 REGULATOR, fluid pressure; see manual 07 7* 6459 ELBOW, street; /8 npt(m) x /4 npt(f) 7 5958 VALVE, shuttle; /8 npt(f) 7 46 CONNECTOR; /8 npt(m) x 5/ in. (4 mm) OD tube 74 59840 ELBOW; /8 npt(m) x 5/ in. (4 mm) OD tube 75 0649 DRYER, air; / npt(f) 76* 579 ADAPTER; /4 npt(m) x / npt(m) 77* 66466 TEE, pipe; /4 npt(f) 78* 8758 BUSHING; /8 npt(m) x /4 npt(f) 79* 44 ELBOW; /4 npt(mbe) 80* 047 REGULATOR, air; with gauge; see manual 0867 8* 66590 ELBOW, street; /4 npt (mxf) 8 0006 BUSHING, pipe; / npt(m) x /4 npt(f) 8 470 ELBOW; /4 npt(m) x /4 in. (6 mm) OD tube Ref. No. Part No. Description Qty. 84 4 CONNECTOR; /4 npt(f) x /4 in. (6 mm) OD tube 85* 45 ELBOW; /8 npt(m) x /4 in. (6 mm) OD tube 86* 458 FITTING, Y-adapter; /4 in. (6 mm) OD tube 87* 5769 ELBOW, street; /4 npt(m) x /8 npt(f) 88 8954 GUN, airspray, AirPro; see manual 44 89 80569 TUBE, extension, gun fluid inlet 90 598095 TUBE; nylon; 5/ in. (4 mm) OD; 55 ft clear; see pages 8 and 40 9 buy locally TUBE; nylon; /4 in. (6 mm) OD; natural; see pages 8 and 40 5 ft 9 buy TUBE; nylon; 5/ in. (4 mm) OD; 50 ft locally red; see pages 8 and 40 9 buy locally TUBE; nylon; 5/ in. (4 mm) OD; 5 ft green; see pages 8 and 40 * These parts are shown on page. These parts are shown on pages 0 and. These parts are shown on page 4. 004G
Parts Part No. 5896 Primer System, Series A, Detail Views Detail A Air Inlet Manifold Assembly Detail B Fluid Regulator Assembly 67 78 8 76 7 79 77 87 85 86 55 85 80 6 69 70 68 74 7 TI584a TI50a Detail C Base and Stand Assembly 7 6 8 5 9 09 6 8 6 6 7 TI58a Detail D Solvent Pump Assembly 55 5 0 9 TI587a 004G
Parts Part No. 490 Proportioner, Series A 9 0, 8 45 0 8 79 7 TI6506a 6 7 9 60 49 48 58 59 40 5 9 6 5 7 5 5 6 4 4 45 48 45 4 (Ref) 4 44 6 7 8 0 4 65 66 Ref. nos. 4, 45, 48, 58, 59, 60, and 6 are shown here but are part of system parts lists on pages 7 or. Ref. nos. 0, 65, and 66 are used on Model 5896 System only. TI6507b 4 004G
Parts Part No. 490 Proportioner, Series A Ref. No. Part No. Description Qty. 5D77 FRAME, wall mount 870 CONTROL, air; see page 4 4 09544 ELBOW, pipe; /8 npt (mbe) 5 6756 ELBOW, street, 45 ; /8 npt (mxf) 6 55665 UNION, adapter; /8 npsm(f) x /8 npt(m) 7 4K977 FILTER, air; 5 micron 8 46 ELBOW; /8 npt(m) x /8 in. (0 mm) OD tube fitting 9 5D795 FILTER, air; 40 micron 0 4870 PNEUMATIC CONTROL see page 4 460 USER INTERFACE; see page 44 48570 PUMP, UltraMix, cst; see 067 4 5D87 BRACKET, support, fluid manifold 5 C8 ELBOW; / npt(m) x /8 in. (0 mm) OD tube fitting 6 C908 WASHER, lock; /4 5 7 95 SCREW, cap, button hd; 5 /4-0 x /8 in. (0 mm) 0 096 SCREW, machine, phillips; 4 8- x 7/6 in. ( mm) 5D767 PLATE, side 99 SCREW, self-tapping 80 SCREW, hex hd, flanged; 8 /8-6 x 5/8 in. (6 mm) 4 0598 HOSE, air; nitrile; / in. ( mm) ID; / npt (mbe); 8 in. (457 mm); see also pages 6 and 40 5 C904 ELBOW, swivel; / npt(m) x / npsm(f) 6 5D607 CABLE, sensor; see Electrical Schematic, page 4 7 5D794 HARNESS, connector; see Electrical Schematic, page 4 8 90 LABEL, warning 0765 GROMMET 0045 COUPLING; /8 npt (fbe) 567 CONNECTOR; /8 npt(m) x /4 in. (6 mm) OD tube 7 4454 GROUND WIRE 8 79 PLUG, tube fitting; 5/ in. (4 mm) OD tube 9 505 NUT, keps, hex hd; 0-4 40 55787 SCREW, cap, button hd; 4 0- x /8 in. (0 mm) 44 404 SCREW, machine; /4-0 x -/ in. (8 mm) 45 594 NUT, hex, flange hd; /4-0 7 48 458 FITTING, Y-adapter; /4 in. (6 mm) OD tube 49 574 ADAPTER; /8 in (0 mm) tube x /4 in. (6 mm) tube Ref. No. Part No. Description Qty. 56 598095 TUBE; nylon; 5/ in. (4 mm) OD; ft clear; see pages 6 and 40 57 buy locally TUBE; nylon; 5/ in. (4 mm) OD; ft black; see pages 6 and 40 58 buy locally TUBE; nylon; 5/ in. (4 mm) OD; ft red; see pages 6 and 40 59 buy locally TUBE; nylon; 5/ in. (4 mm) OD; green; see pages 6 and 40 ft 60 buy locally TUBE; nylon; /8 in. (0 mm) OD; 6.7 see pages 6 and 40 ft 6 645 NIPPLE; /4 npsm x /4 npt 70 buy locally TUBE; nylon; /4 in. (6 mm) OD; see pages 6 and 40 4. ft 79 95889 BUSHING, strain relief Replacement Danger and Warning labels, tags, and cards are available at no cost. 004G 5
Parts Tube and Hose Connections, All Models See FIG. 0. Find the keys on the drawing to ensure proper connections. Key Description Ref. No. (see pages 7,,, and 5) Length, in. (mm) A Dispense Valve A OFF 56 4 (60) A Dispense Valve A ON 57 4 (60) B Dispense Valve B OFF 59 4 (60) B Dispense Valve B ON 58 4 (60) C Air to Pneumatic Control (0) 60 8 (0) D Air Filter (9) Drain Tube 70 4 (60) D Air Filter (7) Drain Tube 70 8 (457) G Gun Air Regulator (74) Input 60 (787) G Gun Air Regulator (74) Output 60 0 (76) L Fluid Line, Pump A to Dispense Valve A 4 8 (457) L Fluid Line, Pump B to Dispense Valve B 4 8 (457) M Air Filter (9) to Air Control () 4 8 (457) P Pump A Input Air 60 7 (4) P Pump B Input Air 60 (5) S Pump A Solenoid Inputs ( tubes) 70 (5) S Pump B Solenoid Inputs ( tubes) 70 (5) T Solvent Pump Air Supply 57 54 (7) 6 004G
Parts P P G G M C G T D M D T P P S S B C D A D B Side L B L A A Side L B B A A L TI6508a FIG. 0. Tube and Hose Connections, All Models 004G 7
Parts Tube and Hose Connections, Model 5896 Only See FIG.. Find the keys on the drawing to ensure proper connections. Connections shown apply only to Model 5896. For connections which apply to all models, see FIG. 0. Ref. No. (see Length, Key Description pages and ) ft. (m) This Key applies to Model 5896 only CB Solenoid to Control Box 90 0 (9.) DB Air Supply to Air Dryer 9 8 (.4) FA Flush Valve A OFF 9 5 (7.6) FA Flush Valve A ON 9 5 (7.6) FA4 Control Box to Shuttle Valve 9 0.5 (0.5) FB Flush Valve B OFF 9 5 (7.6) FB Flush Valve B ON 9 5 (7.6) FB4 Control Box to Shuttle Valve 9 0.5 (0.5) GA Gun Air Supply 7 6 (7.9) GF Gun Fluid Supply 7 6 (7.9) P Tank A to Pump A 8 6 (.8) P4 Tank B to Pump B 8 6 (.8) R Air Supply to Fluid Regulator 9 5 (.5) R Air Signal from Control Box to Fluid Regulator 90 5 (7.6) SA Solvent Pump to Flush Valve A 5 5 (.5) SB Solvent Pump to Flush Valve B 5 5 (.5) TA Tank A Air Supply 9 5 (.5) TB Air Dryer to Tank B 9 5 (.5) 8 004G
Parts B Side A Side SA R SB FA4 FB4 Front View FB FA4 R FB4 TA DB FB FA FA FA FA CB Bottom View FB FB SB SA GA R R GF CB TA DB TB TB B Side A Side Tank A Tank B P4 P FIG.. Tube and Hose Connections, Model 5896 only 004G 9
Parts Pneumatic Schematic MOTOR UP MOTOR B DOWN B PUMP UP, VDC PUMP B B DOWN, VDC MOTOR DOWN A MOTOR A PUMP UP, VDC UP PUMP A A DOWN, VDC AIR EXHAUST, / TUBE X 4" LONG MANIFOLD GAUGE AIR REGULATOR AIR SUPPLY SOLENOID VDC POSITION A METERING VALVE VDC 0 PSI RELIEF VALVE GAUGE /8 AIR FILTER AUTO DRAIN 5 MICRON TO MANIFOLD /8 TUBE SOLENOID POSITION POSITION (OPEN FOR OPT. CIRCULATION ACCESSORY SOLENOID) POSITION 4 (OPEN WITH BLANK PLATE) B METERING VALVE /4 AIR FILTER AUTO DRAIN 0 MICRON /4" BALL VALVE BLEED TYPE AIR REGULATOR SET @ PSI RELIEF VALVE 6 PSI FACTORY SET TURBINE / POWER SUPPLY 40 004G
Parts 870 Pump Air Control Ref. No. Part No. Description Qty. 0 5D84 MANIFOLD, air 0 0697 REGULATOR, air; / npt(f) inlet and outlet; see manual 0868 0 940 CAP, pipe, / in. ( mm) 04 0689 GAUGE, air pressure 05 678 PLUG; /4 npt 06 876 VALVE, ball, bleed-type; / npt(fbe) Ref. No. Part No. Description Qty. 07 498 VALVE, safety relief; 0 psi (0.8 MPa, 8 bar) 08 946 STANDOFF 4 09 0008 BUSHING, pipe; / npt(m) x /8 npt(f) 0 C904 ELBOW, swivel; / npt(m) x / npsm(f) 0 05 04 0 0 08 05 05 07 04 0 09 08 0 06 TI460a 004G 4
Parts 4870 Intrinsically Safe Pneumatic Control 07 0 Alternator Module (04) Detail 0, 4 04d 04a 0 5 04 04e 06 0 04b 04c 08 TI456a Solenoid Module (06) Detail 06g 06f 06h 06f 06d 06a 06e 06n 06m 06s 06p 06t 06f 06n 06k 06j 06n 06c 06b 06u TI4558a 4 004G
Parts 4870 Intrinsically Safe Pneumatic Control, continued Ref. No. Part No. Description Qty. 0 4849 CIRCUIT BOARD, main 0 0005 SCREW, machine, phillips; 8 8- x 5/6 in. (8 mm) 04 45854 MODULE, alternator; includes items 04a-04e 04a 954 GASKET; LDPE foam 04b 5A85 WIRE HARNESS 04c 5 ELBOW; /8 npt(m) x /8 in. (0 mm) tube fitting 04d 480 SCREW; M5 x 5 4 04e 9 TURBINE ALTERNATOR 05 09466 NUT, lock, w/nylon insert; 8-06 4868 MODULE, solenoid, IS; includes items 06a-06u 06a 5A8 MANIFOLD 06b 756 VALVE, VDC, IS 06c 46 FITTING; /8 npt x 5/ in. (4 mm) tube 6 06d 5697 NIPPLE; /4 npt 06e 54 AIR REGULATOR; /4 npt 06f 584 ELBOW; /4 npt x /8 in. (0 mm) tube fitting 06g 6070 ELBOW, street; /8 npt(m x f) 06h 0890 GAUGE 06j 5A798 GASKET, neoprene 06k 5A799 GASKET, neoprene 06m 007 ELBOW; /8 npt (mbe) 06n 04765 PLUG, pipe; /8 ptf 6 06p 57449 MUFFLER 06q 5 WIRE FERRULE, orange (not shown) 8 06r 769 CONNECTOR, position 06s 5078 ADAPTER, /4 x /8 npt 06t 7480 SAFETY RELIEF VALVE, 6 psi (79 kpa,.8 bar) 06u 558 PLATE 07 5A800 GASKET; neoprene 08 44 BUSHING, strain relief 09 06084 SCREW, machine; M5 x 0.8; 0 mm 0 59085 TUBE, poly-flo ft 505 NUT, keps; 0-4 0409 CLAMP, ground 5A849 HARNESS, wire, alarm 4 744 CONNECTOR, plug, 8 position 5 5B090 WIRE, grounding, door 7 07 WASHER, lock, external tooth; M5 8 065 WIRE, copper ft 0 8 TERMINAL, lug, lockwasher 89 SPACER 4 HARNESS, connector 46899 CIRCUIT BOARD 4 5 FERRULE, wire 004G 4
Parts 460 User Interface Ref. No. Part No. Description Qty. 40 5B06 DISPLAY 40 5A85 HARNESS, wire 404 5A80 GASKET; neoprene 405 5D85 KNOB, control 406 5A850 HARNESS, wire 407 5A85 HARNESS, wire, switch 408 5D796 LABEL, control, upper 409 5D798 LABEL, control, lower 40 45706 CIRCUIT BOARD, display; includes jam nut (N) Ref. No. Part No. Description Qty. 4 546 SCREW, machine; 4-40 x /8 in. (0 mm) 4 5A856 PANEL, display 4 C7076 NUT, lock, w/nylon insert; 4-40 4 44 907 MOUNT, tie wrap 46 5A854 HARNESS, wire, display 48 8848 WASHER; 0.0 in. 4 49 066 SCREW, set; socket hd; 0-4 x 5/6 (8 mm) 404 4 48 407 N 408 40 4 406 405 407 49 40 40 409 40 TI4755a 46 406 TI4756a 46 44 004G
Parts 499 Pump Inlet Valve Assembly, for 490 Clear Coat System only 505 504 506 50 Ref. No. Part No. Description Qty. 50 56589 UNION, swivel, 90 ; /4 npt(f) x /4 npsm(f) 50 00505 BUSHING, pipe; /4 npt(m) x /8 npt(f) 50 777 TEE; /8 npt(m) x /8 npt(f) 504 09544 ELBOW, 90 ; /8 npt (mbe) 505 549 VALVE, ball; /8 npt (fbe) 506 6485 NIPPLE; /8 npt x /8 npsm 50 50 504 505 506 TI657a 498 Pump Outlet Valve Assembly, for 490 Clear Coat System only 607 604 60 60 60 605 606 608 60 60 604 607 605 606 605 606 TI655a Ref. No. Part No. Description Qty. 60 568 UNION, swivel, straight; /4 npt(m) x /4 npt(f) 60 0959 CROSS, pipe; /4 npt(f) 60 5697 NIPPLE; /4 npt 604 09 CONNECTOR, pipe; /4 npt (fbe) 605 548 VALVE, ball; /4 npt (fbe) 606 645 NIPPLE; /4 npt x /4 npsm 607 049 ELBOW, 90 ; /4 npt (mbe) 608 00840 ELBOW, street, 90 ; /4 npt (mxf) 004G 45
Parts 496 Dispense Valve Assembly, for 490 Clear Coat System 77 7 70 70 70 74 76 708 77 70 7 70 7 70 70 74 705 704 7 709 707 706 70 TI659a Ref. No. Part No. Description Qty. 70 87 VALVE, dispense; see 0655 70 5D6 HOUSING, ratio 70 454 VALVE, pressure relief 704 578 PLUG, cap; /4 npt 705 5600 ELBOW, 90 ; /4 npt (fbe) 706 770 NIPPLE, long; /4 npt 707 548 VALVE, ball; /4 npt (fbe) 708 04 WASHER, lock 4 709 5697 NIPPLE; /4 npt 70 645 NIPPLE; /4 npt x /4 npsm 7 00840 ELBOW, street, 90 ; /4 npt (mxf) 7 0685 U-BOLT, with nuts; /4-0 7 5F8 BRACKET, dispense 74 6746 FITTING, barbed 76 0970 PLUG, pipe, headless 77 50867 VALVE, check 46 004G
Parts 4987 Dispense Valve Assembly, for 49 Primer System 77 7 70 70 70 74 709, 707, 70 708 7 77 70 70 70 70 704 7 704 7 709 707 74 70 TI655a Ref. No. Part No. Description Qty. 70 87 VALVE, dispense; see 0655 70 5D6 HOUSING, ratio 70 454 VALVE, pressure relief 704 578 PLUG, cap; /4 npt 707 548 VALVE, ball; /4 npt (fbe) 708 04 WASHER, lock 4 709 5697 NIPPLE; /4 npt 70 645 NIPPLE; /4 npt x /4 npsm 4 7 00840 ELBOW, street, 90 ; /4 npt (mxf) 7 0685 U-BOLT, with nuts; /4-0 7 5F8 BRACKET, dispense 74 6746 FITTING, barbed 77 50867 VALVE, check 004G 47
Parts 49 Hose Bundle and Remote Mix Manifold, for 490 Clear Coat System 806e 80 806d 804 80 807 80 806a 805 804 806b 80 804 80 807 80 804 806a 806c TI686a Ref. No. Part No. Description Qty. 80 00840 ELBOW, street, 90 ; /4 npt (mxf) 80 04984 TEE; /4 npt(f) 80 6698 VALVE, ball; /4 npt(m) x /4 npt(f) 6 804 5F74 FITTING, adapter; /4 npt(m) x /4 6 npt(f) 805 440 MANIFOLD, mix, remote; see page 50 806 499 HOSE SET; includes items 806a-806e, and protective cover 806a HOSE, component A; 5 ft (0.7 m) 806b HOSE, component B; 5 ft (0.7 m) 806c HOSE, solvent; 5 ft (0.7 m) 806d HOSE, air; 4 ft (.5 m) 806e 4988 HOSE, whip; with static mixer; 5 ft (.5 m) 807 50867 CHECK VALVE; /4 npt (mbe) 48 004G
Parts 4986 Hose Bundle and Remote Mix Manifold, for 49 Primer System 806e 8 80 804 806d 805 806a 806b 806c TI6409a Ref. No. Part No. Description Qty. 80 6698 VALVE, ball; /4 npt(m) x /4 npt(f) 804 5F74 FITTING, adapter; /4 npt(m) x /4 npt(f) 805 440 MANIFOLD, mix, remote; see page 50 806 4985 HOSE SET; includes items 806a-806e, and protective cover 806a HOSE, component A; 5 ft (0.7 m) 806b HOSE, component B; 5 ft (0.7 m) 806c HOSE, solvent; 5 ft (0.7 m) 806d HOSE, air; 4 ft (.5 m) 806e 4988 HOSE, whip; with static mixer; 5 ft (.5 m) 8 578 PLUG, cap; /4 npt(f) 004G 49
Parts 440 Remote Mix Manifold (490 and 49 only) 9 9 90 90 90 9 9 909 90 907 908 904 905 9 906 90 9 99 98 90 9 97 95 94 98 96 TI6509a Ref. No. Part No. Description Qty. 90 9640 PLATE, mounting, regulator 90 964 GASKET, mix manifold, outlet 90 964 HOUSING, mix manifold 904 964 GASKET, mix manifold, inlet 905 969 BASE, mix manifold 906 68877 HOUSING, regulator 907 700 NUT, cap 908 04 SCREW, set, socket hd; 0- x /4 in. (9 mm) 909 0066 NUT, hex; 0-90 6744 RETAINER, spring 9 6745 SPRING, compression 9 6887 STEM, valve 9 69597 SEAT, valve 94 68879 WASHER, backup 95 78 GASKET 96 780 GASKET, non-metallic 97 78 DIAPHRAGM, regulator 98 6888 WASHER, acetal 99 0980 NUT, hex; 4-40 90 09 SCREW, cap, socket hd; 8- x /8 4 in. (0 mm) 9 5968 SCREW, cap, socket hd; 8- x -/4 in. ( mm) 5 Ref. No. Part No. Description Qty. 9 04 PIN, spring 9 645 NIPPLE; /4 npt x /4 npsm 98 5966 CHECK VALVE; includes item 9 4 90 965 GASKET; acetal 4 9 504 PACKING, o-ring, check valve 4 These parts are included in Repair Kit 440, which may be purchased separately. 50 004G
Technical Data Technical Data Mix ratio range................................. 0.:-0: (in 0. increments) Ratio tolerance range............................ up to +/- % Flow rates Minimum............................... 0.0 qt/min (0.0 lpm)* Maximum............................... gpm (.8 lpm) Pump size..................................... 54 cc/cycle Pump cycle length (one cycle = one upstroke and one downstroke)....... 6 in. (5 mm)/cycle Fluid viscosity range............................. 50-000 cps (heavier viscosities can be mixed with use of optional heaters, heated hoses, and hardware) Fluid filtration.................................. 40 mesh standard Maximum fluid working pressure................... 50 psi (.7 MPa, 7 bar) Air supply pressure range......................... 70-0 psi (490-800 kpa, 4.9-8 bar) Maximum air consumption at 00 psi (0.7 MPa, 7 bar).. 0 scfm (0.56 m /min) Ambient temperature range Operating............................... -04 F (0-40 C) Storage................................ 0-60 F ( -7 C) Environmental Conditions Rating................... Altitude up to 4000 meters Maximum relative humidity to 99% up to 40 C Pollution degree () Sound pressure**............................... 70. dba Sound power**................................. 78.4 dba Wetted parts Pumps................................. See 066 Dispense Valves......................... See 0655 PC Communications............................. RS- * Minimum flow rate is dependent on the material being sprayed and mixing capability. Test your material for specific flow rate. ** Tested in accordance with ISO 744 at 00 psi (0.7 MPa, 7 bar) inlet air pressure. 004G 5
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 () years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Information For the latest information about Graco products, visit www.graco.com. TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 6-6-69 or Toll Free: -800-8-0, Fax: 6-78-505 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 004 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES P.O. BOX 44 MINNEAPOLIS MN 55440-44 USA Copyright 005, Graco Inc. All Graco manufacturing locations are registered to ISO 900. www.graco.com Revised /0